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You may not think about packaging much beyond what it costs, but the real impact of your packaging choices runs deeper than the invoice total. When designs aren’t optimized for freight efficiency and product protection, it not only drives up shipping costs with every order, but can put hard-earned brand trust at risk.
Packaging Design Optimization with Katelynn Geigel
In this behind the scenes video series on packaging design optimization, we sit down with Trillora's Katelynn Geigel, Senior Structural Packaging Designer, to explore the nuances of optimizing packaging for today’s ambitious consumer brands. Join us as Katelynn shares her perspective on transforming packaging from a sourcing challenge into a strategic advantage.
Q: How does a structural designer go about developing the right packaging solution?
This video walks through the detailed process of optimizing packaging suites. From gathering data at distribution centers to analyzing carton sizes and volume constraints, the designer ensures every package fits perfectly within operational limits. After comparing old and new designs, samples are tested to validate the final fit—making the process both precise and rewarding.
Q: What information needs to be gathered in order for packaging optimization to be successful?
This video dives into the hands-on process of packaging optimization at distribution centers. From documenting issues with photos to gathering feedback from floor teams, designers assess product fit, layout, and folding patterns to identify and fix problems. It’s all about improving performance through real-world observation and smart design.
Q: What might surprise someone about the packaging optimization process?
This video explores the often-overlooked factors in packaging optimization. It’s not just about carton size—it’s about understanding product dimensions, order volumes, and how they vary. By analyzing both measurements and quantity data, designers create smarter packaging suites that align with real-world ordering systems, reducing waste and improving efficiency.
Q: What are things you notice about packaging that are not optimized?
Is your packaging truly optimized? In this video, Katelynn, Senior Structural Packaging Designer, breaks down key signs of inefficiency—like excess air, crushed cartons, and damaged products. Learn how material specs, layout, and strength impact performance and cost. Smart design means less waste, better protection, and a smoother customer experience.
Q: How can I tell if packaging optimization is successful?
In this clip, Katelynn dives into where data, design, and optimization come together. From crunching numbers to tweaking suites for better results, it's all about the thrill of seeing the math work out. Packaging is more than just die lines—it’s a puzzle we love to solve.
📗 Read Our Case Study: How Trillora Provided 20% Direct Savings on Packaging for a Premium Shoe Brand
A Proven Packaging Optimization Process for Driving Cost Savings
Optimized packaging has positive ripple effects across a business. Using standardized materials with the right specifications, ensuring items are protected but not overpacked, and designing for maximum cube density have produced significant savings and benefits for Trillora customers.
Explore our packaging optimization process to learn how Trillora helps brands streamline operations and uncover hidden savings in their supply chains.
Get Expert Input on Your Packaging Program
A packaging assessment is the first step in optimizing your packaging program. Our packaging consultants help brands transform their packaging programs to be more cost-effective without sacrificing quality or sustainability. Connect with our experts to get started:
