How to Adapt Your Custom Packaging in a Recession
In the past several years the world has faced economic challenges with the Covid-19 Pandemic, supply chain shortages, Russia-Ukraine conflict and other events which have impacted the global markets, potentially causing a new a recession to occur in the United States. Today, many brands and consumers are starting to cut back to adjust to slower economic growth, rising costs and inflation. Often, many businesses find themselves re-evaluating their packaging expenses as consumers are spending less, brands are charging less, and new potential projects are put on hold.
Many buyers find themselves juggling between quality and cost for their custom packaging. Often, many brands will begin sacrificing quality to compensate for the increased cost, which can be damaging to a brand’s consistency, message, and product quality.
Ultimately, packages still need to provide adequate protection for a product and in most cases, they need to make a product appear attractive on the sales floor and retain brand consistency. As a result, brands need to adapt their custom packaging to work best with a recession.
7 Ways to Adapt Your Custom Packaging in A Recession
Consider Selling Economy Sized Products
In a recession, buyers are much more rational with their purchases and are more likely to buy based on what they need. As a result, you should consider selling economy-sized products or more economical versions of your product. More economical products will help you retain loyal brand customers looking to save on cost or buying from a more rational perspective.
Ultimately, by implementing an economy sized product it enables you to continue preserve branding on your packaging with consistency, while providing adequate protection to your product.
Re-evaluate Your Consumers’ Packaging Preferences
Conditions such as the economy affect your buyers’ buying preferences. Research and evaluate your consumers’ expectations and what they find valuable when it comes to your custom packaging. This can be done with surveys and study groups to analyze consumer behavior and feedback when interacting with your brand and product. Make sure that your audience is a random representative of your target audience to record the most accurate data.
You may find that some packaging features, product information or design are just unessential or unneeded. They may even provide you with insight into what they are willing to pay more for. This can help you allocate your resources in the right place for your custom packaging. After evaluating your consumer’s preferences, adjust your packaging.
Consider Alternative Packaging Products, Materials and Printing Methods
It does not hurt to explore alternative packaging products, materials, and printing methods for your custom packaging, especially if you have received positive consumer feedback to do so. There are many different types of packaging products, material, and print options available that will vary based on your product and budget.
Due to the complexity and versatility of custom packaging, we recommend you speak to a packaging expert for assistance in finding the right alternative packaging options for you. If you do not have a packaging expert, then partner with Brown Packaging today to explore options.
Flexographic Print (Cheaper For Large Quantity Orders)
Digital Print (Cheaper For low Quantity Orders)
*Read “Digital vs. Flexo Print: Which Should You Choose?” for more information.*
Optimize the Size and Shape of Your Packaging
Often, many businesses do consider material costs when selecting the size and shape of their packaging. Typically, this is because they order packaging from an online company that does not provide you with the expertise and service of structural design.
Structural design refers to how a packaging product or object is shaped and sized. If it is a box or display, then the design will include all the cuts and folds with measurements. Structural design can help you optimize the shape and size of your custom packaging, which will lead to lower material usage and costs. Overtime with a large enough volume, this can make a huge difference.
Buy In Bulk
We understand that not everyone can buy packaging in such large quantities as it affects cash flow and inventory levels. However, if you can do so, then we recommend it as the cost per unit decreases as quantity increases. Speak to your current or prospective supplier to explore cost and quantity incentives.
Get Multiple Quotes
Comparing prices from custom packaging companies helps protect you in getting a fair and competitive price. Be sure to request prototypes and samples from each supplier as quality and price will vary from vendor to vendor. Always factor in quality and other factors such as lead time and order minimums capabilities when reviewing a quote.
Partner With the Right Packaging Supplier
Often, selecting the right packaging supplier goes hand in hand with obtaining multiple quotes. Not every vendor is going to be the best fit for your packaging project. Essentially, you want to get a supplier that has the resources, capabilities, and drive to fulfill your project to your expectations.
Typically, custom packaging projects are diverse, complex and require a lot of different resources and capabilities to fulfill. As a result, we recommend you partner with a packaging distributor or hybrid supplier that can accommodate all your packaging needs in one place. These packaging suppliers have an advantage over manufacturers by networking with hundreds of different vendors to get you the best value for your project.
Partner With Brown Packaging
At Brown Packaging, we assign a design package expert to each project to help our customers come up with solutions tailored to their needs. With over 30+ years of experience working with different industries and projects during a recession, we have developed solutions that can accommodate you. Contact us today to get started.
In 2026, sustainability is no longer just a trend—it’s a buyer expectation. Forest Stewardship Council (FSC) certification has become a key benchmark for responsible packaging, signaling that materials are sourced from responsibly managed forests. For packaging buyers, FSC certification is more than a compliance checkbox—it’s a brand value that influences purchasing decisions, retailer acceptance, and customer loyalty. What Is FSC Certification? The Forest Stewardship Council certifies that paper-based packaging materials are sourced from forests managed for environmental responsibility, social benefit, and economic viability. FSC Mix: Packaging contains a blend of FSC-certified and controlled wood. FSC Recycled: Packaging is made entirely from recycled fiber. FSC 100%: Packaging is sourced only from FSC-certified forests. Why FSC Matters to Buyers in 2026 Retail access: Many major retailers now require FSC-certified packaging. Sustainability goals: Aligns with corporate ESG and carbon reduction commitments. Consumer trust: Customers recognize the FSC label and view it as credible. Global compliance: Meets international sustainability regulations. How FSC Certification Strengthens Brand Value Differentiation: Stand out with certified sustainable packaging. Marketing advantage: FSC logos reinforce eco-friendly messaging. Risk reduction: Verified sourcing prevents greenwashing claims. Customer loyalty: Environmentally conscious buyers prefer certified products. Challenges in FSC Implementation Limited supply of certain FSC substrates. Higher costs compared to non-certified materials. Need for supplier audits and documentation. Packaging Solutions with Brown Packaging Brown Packaging partners with buyers to integrate FSC-certified materials into corrugated boxes, folding cartons, and retail packaging. Our solutions support sustainability while maintaining cost efficiency and protection. Contact us to strengthen your brand with FSC-certified packaging. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Consumer Insights on Sustainable Packaging. Retrieved from https://sustainablepackaging.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. (714)300-0650 request@brownpackaging.com Most Recent Posts: Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Sustainable Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Sustainability is now a top priority for packaging buyers. Retailers, regulators, and consumers are all demanding packaging solutions that reduce environmental impact without sacrificing performance. In 2026, buyers must balance eco-friendly materials, cost, and compliance to build programs that are both effective and future-ready. What Buyers Need to Know About Sustainable Packaging Regulatory pressure: Governments are enforcing stricter rules on recyclability and plastic use. Retail mandates: FSC certification and recyclable packaging are becoming standard requirements. Consumer expectations: Customers increasingly choose brands with visible sustainability commitments. Sustainable Material Options Recycled corrugated: High recycled content while maintaining compression strength. Compostable films: Suitable for select food and retail applications. Molded pulp inserts: Replace foam or plastic for protective packaging. Water-based coatings: Enhance moisture resistance without harmful chemicals. Balancing Cost and Performance Right-size packaging: Reduces material waste and shipping costs. Hybrid solutions: Combine eco-materials with corrugated for balance. Life cycle analysis: Evaluate true environmental impact, not just marketing claims. How to Evaluate Sustainable Suppliers Verify FSC, SPC, or ISO certifications. Request testing data for durability and recyclability. Audit supply chains for consistency and transparency. Ensure claims meet local and international compliance standards. Packaging Solutions with Brown Packaging Brown Packaging helps buyers implement sustainable packaging programs that balance cost, performance, and compliance. From recycled corrugated to eco-friendly coatings and inserts, we deliver solutions that meet 2026 sustainability goals. Contact us to explore sustainable packaging options. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Packaging Sustainability Trends and Buyer Insights. Retrieved from https://sustainablepackaging.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Sustainable Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Choosing the right packaging material is one of the most important decisions buyers face. Single-material packaging offers simplicity and recyclability, while multi-material designs provide enhanced performance and protection. Understanding the trade-offs helps companies balance cost, functionality, and sustainability goals in 2026. What Is Single-Material Packaging? Single-material packaging uses one substrate—such as corrugated board, folding carton, or plastic—for the entire structure. Advantages: Easier to recycle and dispose. Lower material costs in many cases. Streamlined sourcing and inventory. Supports sustainability messaging. Disadvantages: Limited barrier protection. Less customization for fragile or complex products. May require added thickness for strength, increasing weight. What Is Multi-Material Packaging? Multi-material packaging combines two or more substrates—such as corrugated with foam, or paperboard laminated with film—to achieve specific performance outcomes. Advantages: Greater protection against moisture, oxygen, and impact. Allows for premium finishes and enhanced graphics. Ideal for fragile or high-value products. Customizable for unique supply chain conditions. Disadvantages: More difficult to recycle due to material separation. Higher cost and longer lead times. Complex sourcing and inventory management. When to Use Each Approach Single-material packaging: Best for products with low fragility, strong sustainability requirements, or cost-driven programs. Multi-material packaging: Best for high-value, fragile, or regulated products requiring advanced protection. Balancing Performance and Sustainability Buyers must weigh performance needs against eco goals: Use recyclable coatings to extend single-material performance. Choose hybrid designs that separate easily for recycling. Apply multi-material solutions only where risk of damage outweighs cost. Packaging Solutions with Brown Packaging Brown Packaging helps buyers evaluate when to use single- vs. multi-material packaging. Our team balances sustainability, performance, and cost to deliver solutions tailored to your supply chain. Contact us to explore the right approach for your products. References Forest Stewardship Council (FSC). (2023). FSC Packaging Certification Guidelines. Retrieved from https://fsc.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.Sustainable Packaging Coalition. (2022). Design for Recyclability and Multi-Material Packaging Report. Retrieved from https://sustainablepackaging.org (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
One of the biggest challenges in sustainable packaging is balancing environmental responsibility with product protection. Buyers often worry that switching to eco-friendly materials means sacrificing durability or driving up costs. In 2026, new material technologies allow brands to meet sustainability goals without compromising strength or supply chain performance. Why Protection Still Matters Damaged products create more waste than packaging ever could. Returns increase logistics costs and carbon emissions. Retailers and e-commerce platforms expect packaging to deliver both sustainability and reliability. Eco-Friendly Material Options Recycled corrugated: Maintains stacking strength while reducing virgin fiber use. Molded pulp inserts: Cushion fragile items while replacing plastic foam. Water-based barrier coatings: Add moisture resistance without plastic films. Compostable films: Ideal for short shelf-life or single-use applications. Paper-based mailers: Replace poly mailers for e-commerce shipments. How to Balance Eco Goals and Protection Use right-sizing to reduce material volume while improving fit. Apply hybrid solutions (corrugated + pulp) for high-value goods. Conduct ISTA testing to validate protective performance. Match material choice to product fragility and supply chain conditions. Examples in Action Electronics: Molded pulp trays replacing EPS foam. Food and beverage: FSC-certified corrugated with recyclable coatings. Retail e-commerce: Recycled paper mailers protecting apparel. Packaging Solutions with Brown Packaging Brown Packaging develops eco-friendly solutions that protect products while meeting sustainability requirements. From recycled corrugated to innovative coatings, our team ensures you never trade protection for environmental impact. Contact us to explore eco-material options. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Eco-Friendly Packaging Materials and Case Studies. Retrieved from https://sustainablepackaging.orgASTM International. (2023). ASTM D4169: Standard Practice for Performance Testing of Shipping Containers and Systems. (714)300-0650 request@brownpackaging.com Most Recent Posts: Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
In today’s competitive market, packaging affordability doesn’t start with cheaper materials — it starts with smarter design. Every score, fold, and insert decision affects not only how a box looks and feels, but how efficiently it’s made, shipped, and used. Structural engineering is the silent driver of cost efficiency — optimizing strength, space, and performance before the first sheet is ever printed. Why Structure Matters More Than You Think The most impactful cost savings in packaging rarely come from supplier discounts; they come from structural efficiency.A box that uses 10% less board but maintains the same compression strength directly reduces both material and freight cost. A redesigned insert that eliminates the need for secondary packaging saves time and labor at the line. Every cut line and fold path tells a story of cost, sustainability, and brand care — and when those align, affordability becomes part of your brand’s DNA. Designing for Efficiency, Not Excess In a market saturated with overbuilt packaging, engineering restraint is a competitive advantage. Structural teams now rely on 3D CAD modeling and virtual prototyping to simulate performance before production — identifying unnecessary material use and structural redundancies. Through precision die-line planning, engineers can improve sheet yield, reduce assembly time, and minimize void space — the dead air that drives up freight bills.It’s not about doing less; it’s about doing smarter. Balancing Protection and Presentation The temptation to “overprotect” products is common — especially in fragile or high-value goods. But protection doesn’t have to mean bulk. Strategic reinforcements, engineered fluting, and interlocking designs can maintain crush resistance and shock absorption while reducing total board weight. For e-commerce and shelf packaging alike, brands can achieve premium presentation with structural simplicity — a key to making packaging both sustainable and affordable. Prototyping to Prevent Waste Prototyping isn’t just for aesthetics — it’s a safeguard against costly production errors.With short-run sample testing and performance mockups, brands can evaluate fit, function, and protection early in development. Adjusting dimensions by fractions of an inch can save thousands in material waste and prevent rejected runs down the line. Smart packaging buyers now view prototyping not as an expense, but as a cost-control strategy that pays dividends in scale. How Structural Design Supports Brand and Budget Affordable design doesn’t mean compromising brand identity — it means integrating brand goals into structure. A well-engineered box reinforces trust, ensures product consistency, and communicates value through precision and fit. When structure, design, and production align, packaging stops being a cost and starts becoming a business asset. That’s where the real savings live — and where long-term brand equity begins. The Brown Packaging Difference At Brown Packaging, every packaging solution starts with structural intent — not guesswork.Our engineering and design teams collaborate to create packaging that performs across shipping, retail, and automation lines, balancing protection, brand visibility, and cost efficiency. We don’t cut corners; we cut waste.That’s how our clients achieve packaging that’s not just affordable — it’s engineered to perform. References Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. PMMI. (2024). Optimizing Structural Design for Packaging Efficiency. Packaging World. (2025). Engineering the Future of Cost-Effective Packaging. Smithers. (2025). Packaging Innovation and Material Efficiency Trends. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Every brand is feeling the squeeze — higher raw material costs, volatile freight rates, and a consumer base more price-conscious than ever. But cutting packaging budgets blindly can lead to damaged goods, compliance issues, and eroded brand value. Smart brands aren’t chasing cheaper boxes — they’re making smarter packaging decisions that balance performance, cost, and perception. The difference between saving money and losing value comes down to how you evaluate your packaging, not just what you pay for it. Beyond Unit Price: Understanding Total Packaging Cost A low unit price might look great on paper — until you factor in assembly time, damage rates, and freight efficiency. Smart packaging evaluation considers the total cost of ownership, including: Material yield (how efficiently sheets convert into boxes) Pallet and trailer utilization (freight optimization) Labor efficiency (ease of assembly or automation compatibility) Product protection (damage rates, replacements, and returns) When buyers assess all these metrics, the lowest-cost box often isn’t the best-value box. Material Selection That Saves in the Long Run Switching materials isn’t just about cutting cost — it’s about reducing waste and improving performance. For instance, moving from double-wall to a high-performance single-wall with better flute structure can cut weight and shipping cost without sacrificing protection. In folding cartons, substrate optimization — using a lighter caliper SBS or switching to coated recycled board — can yield savings that scale across production runs. And for rigid boxes, structural tweaks like thinner chipboard paired with strong wrap papers can preserve presentation while reducing material use. Every small change adds up when you scale across thousands of units. Design Efficiency: The Overlooked Cost Saver A smart structural design can eliminate cost before production even starts. Simplifying folds, reducing glue flaps, or reengineering inserts can cut assembly time and material waste. Modern packaging engineers use CAD-based dieline analysis to optimize layouts — ensuring maximum sheet yield and minimal offcut. For e-commerce and retail brands alike, right-sizing packaging improves shipping efficiency and reduces filler materials while maintaining the brand’s polished look. It’s not just design — it’s design that earns its keep Printing Smart: Matching the Process to the Purpose Not every job needs premium litho or complex spot varnishes. A good packaging partner matches print method to scale and brand intent: Flexo printing for high-volume, cost-efficient runs. Digital printing for short runs, personalization, and multi-SKU campaigns. Litho laminating for high-end visuals in rigid or premium retail displays. By choosing the right print method early, brands can avoid over-engineering — saving both time and money without compromising quality. Data-Driven Decisions: The New Standard for Packaging Buyers Leading companies now use data to guide packaging spend. Damage rate metrics, SKU-level freight analysis, and consumer perception studies all contribute to smarter choices. Smart buyers are no longer asking, “What’s the cheapest box?” They’re asking, “What’s the most efficient box that protects the product, ships well, and supports brand goals?” This mindset shift is what separates cost-cutting from cost control. The Brown Packaging Approach At Brown Packaging, we help brands make smarter packaging decisions by combining engineering analysis, supplier network leverage, and real-world testing. Our process aligns packaging performance with total cost goals — from box design to print selection and logistics. The result: stronger packaging, lower waste, and sustainable cost savings that scale with your business. Because in today’s market, smart packaging isn’t just a cost center — it’s a competitive advantage. References PMMI. (2025). Operational Cost Efficiency in Packaging and Logistics. McKinsey & Company. (2024). Total Cost of Ownership in Consumer Goods Packaging. Packaging World. (2025). Data-Driven Decisions in Packaging Sourcing. Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
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As environmental concerns continue to dominate consumer and regulatory conversations, the packaging industry is responding with innovative, eco-friendly solutions. In 2025, sustainable packaging will not only be a trend but a necessity for businesses looking to reduce their environmental footprint and appeal to increasingly eco-conscious consumers. Here are the top sustainability packaging trends expected to shape the industry in the coming years: Biodegradable and Compostable Materials Recyclable Packaging Solutions Lightweight Packaging Reusable Packaging Systems Plant-Based Packaging Monomaterial Packaging Zero-Waste Packaging Minimalistic Packaging Designs Renewable Energy in Packaging Production Smart Packaging for Sustainability Biodegradable and Compostable Materials The use of biodegradable and compostable materials is on the rise, as more companies turn to alternatives that naturally break down in the environment. Materials such as plant-based plastics, seaweed, and other organic fibers are becoming popular in food and single-use packaging, helping to eliminate waste and reduce landfill use. Recyclable Packaging Solutions Recycling remains one of the most effective ways to reduce waste, and packaging designed for easy recycling is more important than ever. Companies are investing in materials like paper, cardboard, and recyclable plastics, ensuring they are part of a closed-loop system where packaging can be reprocessed and reused multiple times. Lightweight Packaging Lightweight packaging not only reduces material use but also cuts transportation costs and lowers emissions. By using thinner, stronger materials, companies can achieve the same protective qualities while reducing the carbon footprint of shipping. Reusable Packaging Systems Reusable packaging is gaining momentum, with more brands adopting refillable or returnable containers. This trend reduces the need for single-use materials and allows customers to participate in circular economies where packaging is sent back, cleaned, and reused multiple times. Plant-Based Packaging Packaging derived from renewable plant sources like cornstarch, bamboo, and seaweed is an increasingly popular alternative to traditional petroleum-based plastics. These materials are not only renewable but also often biodegradable, making them ideal for a sustainable future. Monomaterial Packaging Monomaterial packaging uses a single type of material, making recycling easier and more efficient. By eliminating the need to separate different components, monomaterial solutions improve recyclability rates and simplify waste management processes. Zero-Waste Packaging The zero-waste movement is pushing companies to rethink packaging entirely. This trend involves designing products with no waste in mind, where all packaging components are either reusable, recyclable, or compostable. Zero-waste solutions aim to minimize the overall environmental impact throughout the packaging lifecycle. Minimalistic Packaging Designs Minimalistic designs reduce the amount of material used in packaging, aligning with sustainability goals. Brands are opting for simple, streamlined packaging that uses fewer resources and emphasizes eco-friendliness, appealing to consumers who prioritize environmental responsibility. Renewable Energy in Packaging Production More companies are shifting toward using renewable energy sources in the production of their packaging materials. By adopting solar, wind, and other clean energy solutions, businesses can reduce their reliance on fossil fuels and cut down on carbon emissions, contributing to a greener supply chain. Smart Packaging for Sustainability Smart packaging solutions are emerging as a way to improve supply chain efficiency and reduce waste. By using RFID tags, QR codes, and other technologies, companies can track packaging materials, monitor product conditions, and optimize inventory management, ultimately minimizing the environmental footprint of packaging. These sustainable packaging trends are set to lead the industry into a greener, more eco-friendly future in 2025. By staying ahead of these developments, businesses can not only meet regulatory requirements but also exceed consumer expectations for environmentally responsible packaging solutions. If you are interested in sustainable packaging solutions, then partner with Brown Packaging today. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Stock Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Roll stock flow wrap packaging is a versatile and efficient method used in the food and packaging industry to package a wide variety of products. It’s commonly used for packaging items like candy bars, cookies, granola bars, crackers, and even non-food items like soap bars and disposable razors. In this blog, we will delve into what roll stock flow wrap packaging is, how it works, its advantages, and some key considerations for businesses looking to implement this packaging solution. What is Roll Stock Flow Wrap Packaging? Roll stock flow wrap packaging, also known as horizontal form-fill-seal (HFFS) packaging, is a process that involves wrapping a continuous roll of flexible packaging material around a product or a group of products and then sealing it to create a sealed pouch or package. This packaging method is highly efficient and can accommodate a wide range of product sizes and shapes. The process of roll stock flow wrap packaging typically involves the following steps: Material Unwinding: A roll of flexible packaging material (often made of materials like plastic films or laminates) is mounted on a machine. This roll contains pre-printed or clear film, depending on branding and product visibility requirements. Product Feeding: The products to be packaged are fed into the machine’s conveyor system. These products can be singular items, such as candy bars, or multiple items bundled together, such as a pack of cookies. Film Forming: The packaging machine forms the flexible film into a tubular shape around the product or product group. The film is wrapped tightly around the product(s), ensuring a snug fit. Sealing and Cutting: The film is sealed along its length and width, creating individual pouches for each product or product group. Simultaneously, a cutting mechanism severs the pouches from the continuous roll. Product Discharge: The finished packages are discharged from the machine’s conveyor belt, ready for further handling, labeling, and distribution. Advantages of Roll Stock Flow Wrap Packaging: Roll stock flow wrap packaging offers several advantages that make it a popular choice for many businesses: Efficiency: This packaging method is highly automated, allowing for rapid production rates and reduced labor costs. Versatility: Roll stock flow wrap machines can handle a wide range of product sizes, shapes, and types. Whether you’re packaging individual items or multi-packs, this method can adapt. Product Protection: The tightly wrapped film provides a barrier against moisture, dust, and contaminants, ensuring the product’s freshness and integrity. Customization: Packaging materials can be customized with branding, labels, and graphics to enhance product visibility and appeal. Cost-Effective: Roll stock packaging materials are generally cost-effective, and the efficiency of the process helps reduce overall packaging costs. Reduced Material Waste: The form-fill-seal process minimizes excess packaging material, reducing waste and environmental impact. Considerations for Implementing Roll Stock Flow Wrap Packaging: Before implementing roll stock flow wrap packaging in your business, consider the following key factors: Product Type: Ensure that your products are suitable for this packaging method. Products with irregular shapes, sharp edges, or those that are extremely delicate may require special considerations. Machine Size and Speed: Choose a machine that matches your production requirements in terms of speed and capacity. Material Selection: Select appropriate packaging materials that align with your product’s shelf life, protection needs, and branding goals. Maintenance and Training: Regular maintenance and operator training are essential for optimal machine performance and product quality. Regulatory Compliance: Ensure that your packaging meets all relevant regulatory requirements for food safety, labeling, and environmental considerations. Cost Analysis: Evaluate the overall cost-effectiveness of roll stock flow wrap packaging for your specific products, considering the initial investment in machinery and ongoing operational costs. Roll stock flow wrap packaging is a versatile and efficient packaging solution that can enhance your product’s presentation, shelf life, and cost-effectiveness. By understanding the process and considering the relevant factors, businesses can make informed decisions about adopting this packaging method to meet their specific needs. If you are interested in roll stock flow wrap packaging, then partner with Brown Packaging today to get started. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Roll Stock Facebook Twitter LinkedIn Pinterest Relevant Posts
Printed boxes are an excellent choice for enhancing brand visibility and creating a memorable unboxing experience for customers. However, a common concern is whether they maintain their aesthetic appeal after enduring the shipping process, which often involves rough handling, exposure to dirt, and environmental factors. In this blog, we’ll explore the challenges of keeping printed boxes looking great during shipping and share actionable tips to ensure your packaging stays pristine and professional, no matter the journey. Why Do Printed Boxes Get Dirty or Damaged During Shipping? Shipping environments can be harsh on packaging, especially when boxes are subjected to: Rough Handling: Boxes are frequently tossed, stacked, and dragged, which can cause scuffs, tears, or dents. Environmental Exposure: Rain, humidity, or dusty conditions can leave marks or stains on your boxes. Extended Transit Times: Longer journeys increase the risk of damage due to repeated handling and exposure. These factors can affect the appearance of printed designs, potentially diminishing the customer experience. How to Keep Printed Boxes Looking Great During Shipping Choose Durable Materials The quality of your box material plays a key role in protecting its appearance. Use corrugated cardboard with a robust outer liner for extra durability. Opt for laminated or coated surfaces to resist dirt, water, and scratches. Consider using kraft exteriors for rugged protection, with printed branding on the interior for a surprise-and-delight unboxing moment. Protect Your Print Design with Finishes A protective finish can safeguard your printed design against smudges, scratches, and moisture. Popular options include: Gloss Lamination: Adds a shiny finish that repels dirt and fingerprints. Matte Lamination: Offers a sophisticated, non-reflective look while protecting the print. UV Coating: Provides extra durability and is ideal for vibrant colors. Use Protective Shipping Features Additional shipping precautions can help reduce wear and tear. Add shrink wrap or polybag covers to shield boxes from dirt and moisture. Use double-boxing for high-value shipments to protect printed boxes during transit. Include void fillers like packing paper or air pillows to minimize movement inside the box. Avoid Overly Dark Designs on High-Impact Areas Dark colors, especially on corners or edges, are more likely to show scuffs or scratches. Reserve darker hues for less exposed areas of the box. Use lighter, neutral tones or patterns that help conceal minor wear. Choose Strategic Placement for Printing Where you print on the box matters. Print your branding or designs on the top and sides, leaving the bottom unprinted to reduce visible wear. For a luxury feel, consider printing inside the box to protect your design while providing a clean unboxing experience. Why Maintaining Box Aesthetics Matters The appearance of your packaging has a direct impact on your brand perception: First Impressions: A box that looks professional upon arrival reassures customers about your product quality. Brand Visibility: Pristine printed boxes keep your logo and messaging clear, acting as mobile advertisements during transit. Customer Loyalty: Packaging that withstands shipping challenges shows customers you value their experience. Conclusion Printed boxes can maintain their beauty and functionality during shipping with the right materials, finishes, and protective strategies. By investing in durable designs and smart shipping practices, you can ensure your packaging arrives looking as great as when it left your facility. If you are interested in quality printed corrugated boxes, then partner with Brown Packaging today to get started. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts