Good packaging starts long before production. A well-designed corrugated box must protect the product, fit efficiently into storage and transport systems, use material economically and remain practical to manufacture and pack.
At Pack & Roll, we design corrugated packaging around the actual product and its logistics requirements. Whether you need a standard shipping case, a custom die-cut box, shelf-ready packaging or protective inserts, our design process focuses on creating a practical solution that performs reliably throughout the supply chain.
Designed Around Your Product and Logistics
The first step in packaging design is understanding what the packaging needs to do. Product dimensions alone are not enough. We also consider weight, quantity per box, product strength and sensitivity, handling requirements, storage conditions and the way the finished packages will be stacked and transported.
Where possible, pallet utilisation is also considered during the design stage. Choosing suitable box dimensions can reduce unused space on the pallet, improve load stability and help make warehouse and transport operations more efficient. Corrugated packaging can be tailored to standard pallet dimensions, allowing better use of available storage and vehicle capacity.
For a new project, customers can provide the physical product or a dimensioned technical drawing together with the relevant weight, quantity and handling information. These details form the basis of the structural design.
FEFCO-Based and Fully Custom Designs
Where suitable, we use internationally recognised FEFCO packaging designs as a starting point. The FEFCO Code is the internationally applied classification system for corrugated packaging structures and provides standard references for commonly used box types. Its purpose is to simplify communication between packaging manufacturers and customers across different countries and languages.
Standard FEFCO constructions can then be modified to suit a particular product, or a completely custom structure can be developed where required. The current FEFCO design library includes slotted boxes, telescopic boxes, folder boxes and trays, retail and e-commerce packaging, as well as interior fitments. Once the structure has been selected, our designers create the digital flat layout and add any required structural details, openings, locking features, inserts or other elements needed for the application.
Choosing the Right Corrugated Board
The packaging structure and the board grade must work together. Corrugated board is available in different flute profiles and material combinations, each providing different characteristics in terms of rigidity, cushioning and compression strength.
The strongest possible material is not automatically the best solution. Effective packaging requires the right balance between product protection, material use and cost. Too little packaging may increase the risk of damage, while unnecessary over-packaging adds material, weight and expense without providing useful additional protection. Our material selection therefore considers the weight and characteristics of the product together with the expected stresses during handling, stacking, warehousing and transport.
From Digital Design to Physical Prototype
Once the proposed structure has been developed and the quotation approved, a physical prototype can be produced before series manufacturing. This allows the actual product to be placed into the packaging and the dimensions, fit, folding and functionality to be checked in practice. Pack & Roll follows this design-to-sample workflow as part of its packaging development process.
Prototyping is particularly valuable for custom die-cut packaging, internal fitments and products with unusual shapes, where relatively small structural changes can significantly improve protection or ease of packing. Any necessary adjustments can then be incorporated into the final production design.
Packaging Designed for Efficient Production
A successful packaging design must also be practical to manufacture. The structure needs to work reliably with the selected production processes, such as cutting, die-cutting, printing, folding and gluing. Manufacturing efficiency is important because the overall cost of packaging is influenced not only by the amount of board used, but also by production efficiency, packing time, handling and waste. By considering these factors during the design stage, we aim to create packaging that is technically appropriate, economical to manufacture and efficient to use.
Packaging Design from Pack & Roll
Pack & Roll has been designing and manufacturing corrugated packaging since 1996. Our team supports projects from the initial product information and structural concept through digital design, prototyping and final production. Whether you already have an existing packaging specification or are developing a completely new product, we can help create a corrugated packaging solution tailored to your product, production process and logistics requirements.
Send us your product or technical drawing together with its dimensions, weight and required quantity, and we will help develop the right packaging solution.