How Trillora and Barebones collaborated
Barebones sent product and packaging samples to Trillora’s U.S. design and engineering team for evaluation. Our team developed new packaging design concepts and material specifications for improved strength, then presented their work to the Barebones product team.
Once concepts were approved, Trillora’s designers ran prototypes from domestic materials through a series of ISTA testing in the lab to ensure designs would withstand the demands of an international supply chain. After the prototypes passed ISTA testing, we sent production files to our team in China, where samples were manufactured from local materials to be used for actual production and a second round of ISTA testing.
With ISTA testing successful, the new designs were ready for mass production and delivery to Barebones' factory.
The old design featured bulky molded pulp trays that wrapped around Barebones’ lantern product, reducing visibility. Trillora’s design featured a larger opening for better product visibility and used a lower profile corrugated insert to hold the product securely in place. That allowed Trillora to decrease the outer dimensions of the box and reduce the amount of materials used, helping to reduce waste and minimize environmental impact, aligning with Barebones’ B Corp. commitments. It also increased freight density, an added bonus.
The main areas where we were able to help improve the packaging was the visual impact of the product on shelf and its sustainability. In addition, we tested the concepts to ensure they will make it through the supply chain without damaging the product.”
- Katelynn Denning, Senior Structural Packaging Designer, Trillora Packaging Solutions
Original packaging on bottom with molded pulp trays.
On top, Trillora’s new design prototype, which was smaller and used corrugated inserts.
Trillora’s new package design, with updated materials and branding. The new packaging was made from lighter and stronger materials, and the decrease in size provided freight savings for Barebones.
Scaling our packaging optimizations
With a successful rollout of our initial packaging program improvements, Barebones has since worked with Trillora to improve quality and performance across more of its of factories and an expanding product line, including expansion of production to Pakistan.
With packaging production under control, Trillora’s team developed additional improvements to ensure retail and transport packaging would be designed in tandem. Merging these two previously separate processes led to pallet optimization and more efficient use of warehouse space.
