When should you engage a structural engineer?

When you are looking at your next packaging project it is easy to think you can do it yourself, since, really a box is a box is a box, right? That could not be further than the truth. Working with the right company and the right structural engineer will save you time and money in the long run. So please, resist the temptation to go it alone!

Often customers come to us after they have tried to go it alone. When coming to us they typically have made one or more of the following mistakes with their design:

  1. They rush through the structural and art layout process.
  2. They opt to create the structural design in-house or change the design we created.
  3. They chose to do the graphic design work in-house.

Two open purple cardboard boxes of different sizes, reminiscent of sleek packaging solutions. The larger box is on the left, and the smaller one is on the right. Both boxes have flaps open, with sharp graphics and the phrase "LIVE YOUR DHARMA" printed in white on the inside of each shipping container.

The benefits of utilizing an experienced professional.

  1. Shipping cost savings resulting from proper sizing

A smaller box is always going to be less expensive than a larger box. A smaller box represents a lower weigh for inbound and outbound shipping costs. Inbound freight cost refers to freight from our plant to yours. A smaller box is less expensive because we can stack more boxes per pallet.  Outbound freight is the cost of shipping your product to your customers. A good structural designer understands dimensional (DIM) weight and size and they understand how even adding one unnecessary 1/16 of an inch to any dimension can add as much as $1.00 shipping cost per package.

  1. Storage cost savings

As mentioned above, a smaller box will lead to lower freight costs. In addition, a smaller carton allows more boxes to be placed on a pallet. This is really important if you are shipping your boxes to a co-packer or a fulfillment operation like a 3PL. As you know, they will charge you for storing your products as well as your packaging. More boxes per pallet/ per month equals lower the overall cost.

  1. A better look, less damage and happier customers

the unboxing experience is a thing! Because of that, we are always concerned about the esthetic and understand the “wow factor” better than most. The goal is always the same, impress the your customer the moment they open the box. Things we consider to make that happen are: how easy is the box is to open, how is the product being shipped presented within the carton. Which is tied to how well the product is secured and protected during shipment. You never want your product to arrive damaged or in disarray, first impressions are critical. And product return, credit and/or replacement is extremely costly.

 

The image shows an open cardboard package from Warby Parker. The inner flap reads, "Good things come in fives: Starfish, Five Senses, High-five, Pentagons, Our Home Try-On." The outer flap says "Good things await you" and "GET EXCITED!" The exterior is black with the Warby Parker logo.

Here are Packaging Design we have experienced structural designers and are ready to assist you with your next packaging project! Give us a call at 630-323-1354 or email us directly at info@pack-design.com