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4 Market ability, performance, functionality,

efficiency, economics, the environment, safety
and regulatory implications can influence any
product / package design process.
4 Involvement from many different departments is
needed to successfully launch a new product /
package combination (Engineering, Marketing,
Purchasing, Regulatory, Manufacturing, Quality
Control, Safety etc.)

4 Rn in depth review of the product / package

requirements should be utilized to outline a
project time line to assure the combined product /
package requirements will be met.
4 R time line cannot be accurately identified without
a thorough review of all aspects.
4 R major cause for time line extension is over
simplification during the project planning phase.


$ Project Start,
Regular Updates and Summary
4 che project start meeting takes place to introduce the
team members, discuss the technical aspects and
create a time line draft.
4 Regular update meetings should occur at a frequency
that supports the complexity of the project.
4 R summary meeting is held to identify any key
learnings that should be applied to the next project.
4 %&%
$ Samples are a very critical
technical aspect associated with the Package
Development Process. Samples of each component
as well as the overall configuration should be
technically developed, reviewed and approved.
4 Prototype samples are needed to test ideas, show
concepts, confirm sizing, styles and materials. R final
approved prototype sample is needed prior to
reviewing the feasibility and financials of a project.
4 Production sample runs are needed for qualification /
validation purposes, sales samples, equipment
testing, material testing, additional package testing
and / or a combination of any of these.

4 &  
'( )c 
$ Is completed to
confirm that the packaging has been designed and
selected appropriately to protect the product in transit
through the distribution cycle.
4 ) # %  *c 
$ Is
completed to confirm that the packaging materials do
not negatively effect the product in any way and vise

 )$ Rre conducted to test
the effectiveness of an innovative packaging
application from functionality and consumer
preference perspectives.

4 O %

ciming to support this aspect should always be
added to the time line if applicable, as it often is the
longest period. Often other aspects such as art
development can be completed in parallel.
4  &%
$ Often a common reason for time
line extensions are the number of renditions created
leading up to the final approved version. cime should
be alloted for graphic development, mock ups,
approvals, revision, regulatory review and pre press


$ che printing aspect can vary dramatically
depending on the requirements. cypically, printing
can take anywhere from 2-8 weeks depending on the
printer's schedule, as well as the size and complexity
of the job.
4     %
$ Certain common materials
can be obtained readily and others may come from
other countries or be manufactured during a specific
time frame. ciming of this aspect (and printing if
applicable) are major influences on the typical lead
time scheduling and should always be considered.

$ Rll documentation development,
review and approval should be completed prior to the
first production run of a new item. Documentation can
include material specifications, process specifications,
finished product specifications, technical drawings,
regulatory documents, testing protocols and data, art
proofs, etc..

4 ) 
$ chis date can be
identified once the final production materials
delivery information has been confirmed. R time
buffer should be considered for the first run to
accommodate new learning curves.
4 ·   & $ ciming for the start shipping
date should be based upon the first lot availability
timing after inspection.
4 Utilized to identify the feasibility of a particular
new item and evaluate all pertinent aspects of the
new package / product combination launch.
4 Is a report comprised of multiple sections
generally including the project scope, required
packaging materials with costs, special product
handling requirements and / or regulatory
aspects, change parts & tooling / equipment or
capital requirements, testing requirements,
product availability, implementation time line and
unit load pack out specifications.
 c "#   

4 + $ co create a new package
system that can be utilized for shipping fragile
items and electronics.
$ ‰ccurred over an 8
month period. It could take 8 weeks to years to
develop and launch a new item. Pharmaceutical
companies may take 2-3 years to launch a new
drug when a food company may introduce new
concepts every quarter. Package development
and product development are often completed in
4 %&%
$ ü prototype concepts
were developed prior to the final concept approval.
Rll were designed with CRD and made by hand.
4 &  
'( )c 
$ che final concept
was tested in a laboratory setting to confirm the
product protection characteristics.
4 · *
*$Îased upon the distribution
hazard performance results, the cost analysis, the
regulatory review and the production testing, it
was determined that the concept launch was

4 c

) $ Special jigs were created
to assist the Rbbey Group with the assembly of
the Suspension Pack. Sealing and cutting dies
were created for the pouch making portion of the
project. Rdhesive transfer tape guns were
obtained to assist the Rbbey Group with the
assembly as well.
material, corrugated, case sealing glue and
adhesive transfer tape were obtained a few
weeks prior to the first production run.

4 &%
$·inished packaging
specifications, assembly work instructions, a
quality control protocol, technical drawings and
contractual documents were prepared for this
4 ·   ) 
$che first run began
slowly and began to pick up after the first 3 hours.
chere was intense supervision during the start
4 6,- *
$ che first
production trial lot was inspected entirely such
that the best possible product was sent to the
4 co   allow marginally produced product
created during the learning curve to be
shipped to the customer.
4 co identify any key learning experiences that
can be applied to the next production run or
concept design.
c $   % &    
4 che package / product system can be designed
utilizing the most appropriate cost effective &
functional materials for the application.
4 Rll pertinent parties can be assured that their
needs and level of involvement are
accommodated during the planning and design
phase, therefore improving the end result and
level of success.
4 chrough the utilization of a packaging feasibility
report, price point determination can be most
accurately identified to prevent margin
c $   % &    
4 R project time line provides validity to the
estimated development and implementation
timing. Rll critical aspects identified during the
planning phase should be included on the time
4 Rn accurately maintained time line serves as the
single most important communication tool for
launching a new or modified item smoothly and
che Effects Package Development can
have on Product Quality and Perception
4 Strengths, weaknesses and opportunities for
margin improvement are identified during the
distribution hazard / product compatibility testing
and clinical studies, as well as the first production
4 che various documentation generated during the
development process maintains the historical,
technical and legal information that is utilized for
ongoing production runs and continuous
improvement. Rccurate documentation can help
facilitate consistency and repeatability as well as
show validity and build customer confidence.

Rs many believe their ambition and ideas can move
mountains (and in most cases they can), the old
saying still goes, ³Rome wasn't built in a day´
With proper planning, time and resource allocation,
it has been proven time and time again that great
things are worth great effort.
4 R copy of this presentation is available by
contacting: Gus Castle (315) 226-1000, Many chanks.........