Packaging Design & Engineering
Packaging design is about more than appearance. A successful package must also function with the product, components, manufacturing process, filling environment and commercial requirements of the program.
Empire EMCO helps manufacturers translate packaging concepts into practical solutions by connecting design, engineering, sourcing, tooling, component selection and manufacturing considerations.
Depending on the project, that may mean evaluating an existing package, modifying stock components, engineering a hybrid stock-and-custom solution, or developing a completely new custom bottle, jar, closure or other component.
What Does Packaging Design & Engineering Include?
The level of engineering support depends on the packaging challenge. Some programs require only component evaluation, while others involve complete structural package development.
Concept Development
Translate a product, marketing or packaging idea into a defined package direction that can be evaluated technically.
Structural Package Design
Develop bottle, jar, closure or component geometry around the needs of the product and packaging program.
Component Integration
Evaluate how containers, closures, pumps, sprayers and other package components work together as a complete system.
Engineering Drawings
Develop and review technical package information used to define the design before tooling and production.
Manufacturing Review
Consider how the package design relates to the intended manufacturing process and production requirements.
Tooling & Commercialization
When new tooling is required, engineering continues through mold development, sampling, approval and commercial production.
How Does a Packaging Design Project Develop?
Packaging development is an iterative process. Each stage helps move the original idea closer to a package that can be manufactured and commercialized.
Define
Identify the product, package, functional, branding and manufacturing requirements.
Design
Develop or refine the package geometry and component strategy.
Engineer
Review technical requirements and translate the design into engineering documentation.
Validate
Evaluate prototypes, tooling samples or other development samples as appropriate.
Commercialize
Move the approved package toward production and commercial use.
What Information Helps Define a Packaging Design?
Better design decisions begin with understanding what the finished package needs to accomplish.
Define the Package
- Package type
- Desired capacity
- General shape and dimensions
- Material preferences
- Neck finish requirements
- Closure or dispensing requirements
- Decoration considerations
Define How the Package Will Be Used
- Product being packaged
- Filling and manufacturing requirements
- Functional performance needs
- Distribution considerations
- Projected production requirements
- Target launch timing
- Future package-family plans
Turning a Design Into a Manufacturable Package
A package can look excellent on a screen and still require engineering changes before it is ready for manufacturing.
Engineering review helps connect the design intent with the technical requirements of the package, components, tooling and manufacturing process.
This step is especially important for custom bottles, jars, closures and specialty components that require new mold development.
Package Design Considerations
- Overall package geometry
- Structural features
- Neck finish and closure interface
- Material requirements
- Manufacturing process
- Tooling requirements
- Package size and capacity
- Production requirements
- Compatibility with the complete packaging system
Packaging Drawings & Design Documentation
Drawings help turn the package concept into technical information that can be reviewed, revised and approved before mold manufacturing proceeds.
Concept Drawings
Early drawings help communicate the package direction, major design features and overall geometry while the project is still being developed.
Technical Drawings
Engineering documentation provides more detailed package information for technical review and further development.
Final Revision Drawings
The approved package concept is converted into the Final Revision Drawings used to confirm the package design before mold manufacturing proceeds.
Engineer the Complete Packaging System
The container is only one part of the finished package. Good packaging development considers how the components work together.
Container
Bottle, jar, tube or other primary package.
Closure
Cap, dispensing closure or other closing system.
Dispensing
Pumps, sprayers and other application components.
Decoration
Color, graphics and other appearance requirements.
Sometimes the most effective solution is a completely custom package. Other times, the best design combines stock and custom components into one coordinated system.
Stock, Hybrid or Fully Custom?
Packaging engineering can help determine how much of the package actually needs to be customized.
Start With Existing Components
An existing package may already meet the major structural and functional requirements of the project.
- Existing bottle or jar
- Existing neck finish
- Stock closure or dispenser
- Customization through color or decoration
Marry Stock & Custom Components
A custom-looking package does not always require every component to be custom.
- Custom bottle + stock closure
- Stock bottle + custom closure
- Custom bottle + existing dispensing system
- Existing package + specialized component
Develop a New Package
When existing components cannot provide the required design or functionality, new package geometry and tooling can be developed.
- Custom bottle design
- Custom jar design
- Custom closure development
- Specialty components
- Custom mold development
Prototyping, Sampling & Package Evaluation
A design is not finished simply because the drawing is complete. Development may continue through prototypes, mold samples and production evaluation.
The specific validation process depends on the package and project. For a custom mold program, engineering samples provide an opportunity to review the package produced from the completed tooling before production approval.
When revisions are required, engineering feedback can be used to determine what changes should be made before the project moves forward.
Evaluation May Include
- Concept review
- Drawing review
- Prototype evaluation when appropriate
- Engineering sample review
- Component fit review
- Required design revisions
- Production approval
Planning Multiple Package Sizes?
Packaging engineering can also evaluate whether multiple related bottle sizes should be developed as part of a coordinated family mold strategy.
A family mold may use a common mold base with interchangeable inserts to support multiple compatible package sizes or variations.
Design Today's Package With Tomorrow in Mind
Packaging programs often expand beyond the first bottle or SKU.
Considering future capacities, related products and additional package sizes during the initial design stage may create more opportunities for coordinated tooling and a consistent package family.
Consider Sustainability During Package Design
Sustainability is easier to evaluate when it is part of the packaging-development conversation rather than an afterthought.
Depending on the project, design and engineering teams may consider material options, PCR objectives, lightweighting and other packaging strategies alongside performance and manufacturing requirements.
Evaluate Sustainability With Performance
- Material selection
- PCR considerations
- Lightweighting opportunities
- Package performance
- Manufacturing requirements
- Product compatibility requirements
- Commercial objectives
Questions That Help Define a Packaging Engineering Project
You do not need to have every answer before contacting Empire EMCO, but these questions can help establish the right development path.
Continue Your Packaging Development Research
Customization Overview
Explore stock, hybrid and fully custom ways to build a package around your product requirements.
Explore Customization →Custom Mold Development
Learn how a custom package moves from concept and engineering through tooling, samples and commercialization.
Custom Mold Development →Family Mold Design
Learn how related package sizes may be developed around a common tooling platform with interchangeable inserts.
Explore Family Molds →Custom Mold Library
Explore existing custom packaging molds that may provide a starting point for a new packaging program.
Browse Custom Molds →Frequently Asked Questions
Common questions manufacturers ask about package design, engineering, drawings, tooling and development.
What is packaging design and engineering?
Packaging design and engineering is the process of developing a package that combines the desired appearance with the structural, functional and manufacturing requirements needed for commercial production.
What is the difference between packaging design and packaging engineering?
Packaging design defines the intended package form, appearance and user experience, while packaging engineering evaluates the technical requirements needed to manufacture and use the package. In custom packaging development, the two disciplines work together.
Can Empire EMCO help design a custom bottle?
Empire EMCO supports custom packaging development from concept and engineering through drawings, tooling, samples, production approval and commercialization.
Do I need a custom mold to create custom-looking packaging?
Not always. Existing stock packaging can often be customized through color, decoration or component selection. A hybrid approach can also combine a custom bottle with a stock closure, or a stock bottle with a custom closure, to create a differentiated finished package.
What are Final Revision Drawings?
Final Revision Drawings are the approved technical drawings used to confirm the package design before custom mold manufacturing proceeds.
What information is needed to begin a packaging design project?
Helpful information can include the product being packaged, desired capacity, package type, material preferences, closure or dispensing requirements, existing samples or drawings, production requirements and target launch timing.
Can packaging engineering help with closures and dispensing systems?
Yes. Packaging engineering should consider the container and its components as a complete system. This may include neck finish, closure fit, pumps, sprayers and other dispensing requirements.
Can multiple bottle sizes be designed as one packaging family?
Potentially. When package designs and manufacturing requirements are compatible, a family mold strategy may use a common mold base with interchangeable inserts to support multiple related package sizes.
Is sampling part of packaging engineering?
Sampling can be an important part of the development process. For custom tooling projects, engineering samples allow the package produced from the completed mold to be reviewed before production approval.
Can sustainability be considered during packaging design?
Yes. Depending on the project, packaging design can evaluate material selection, PCR objectives, lightweighting and other sustainability strategies alongside performance and manufacturing requirements.
Have a Packaging Idea That Needs Engineering?
Bring us the concept, an existing package, a drawing or simply the problem you are trying to solve. Empire EMCO can help evaluate the design, components, engineering requirements and development path needed to move the package toward commercial production.