Case Studies

Challenge

A major FMCG manufacturer was experiencing high levels of transit damage and rising packaging costs. Their corrugated packaging had not been reviewed in over five years, and specifications were based on legacy decisions rather than current supply chain requirements.

Solution

I conducted a comprehensive packaging review across their product range, testing existing specifications and benchmarking against current market options. This included ISTA testing, supplier benchmarking, and a complete redesign of their outer case specifications.

Results

Challenge

A healthcare products company needed to reduce plastic usage across their packaging range to meet corporate sustainability targets and upcoming EPR legislation changes. They also wanted to reduce overall packaging costs.

Solution

I reviewed their complete packaging portfolio, identifying opportunities to replace plastic components with corrugated alternatives, reduce material weight, and improve recyclability. I also managed a supplier tender to ensure competitive pricing for the new specifications.

Results

Challenge

An ecommerce retailer was facing high return rates due to transit damage and customer complaints about excessive packaging and void fill. Volumetric shipping charges were also significantly above industry benchmarks.

Solution

I implemented a packaging right-sizing programme, designing bespoke ecommerce packs for their top-selling product ranges. This included ISTA 6-SAMSCLUB testing, elimination of plastic void fill, and introduction of an improved unboxing experience.

Results