Structural Design Solutions

January 2006
Structural Design
Solutions
 ACKNOWLEDGMENTS AND SOURCES

This publication was written by Mr. Neil C. Robson, International Consultant and former
ITC Senior Adviser in Export Packaging.

More detailed information regarding packaging can be obtained in the following PACKit
Modules:
Importing Exporting
Products Materials “Cross–cutting”
countries countries
1 – Castings and 1 – Paper and 1 – EU 1 – Cuba 1 – Transport
Forgings Board
2 – Chemicals 2 – Plastics 2 – Germany 2 – Ghana 2 – Packaging Design
3 – Cut Flowers 3 – Glass 3 – Netherlands 3 – India 3 – Health, Safety
and the Environment
4 – Dried Fruits and 4 – Metal 4 – USA 4 – Jordan 4 – Packaging and
Dehydrated Vegetables Marketing
5 – Fish and Seafood 5 – Wood 5 – Latvia 5 – Printing and
Packaging
6 – Food 6 – Malaysia
7 – Fresh Fruits and 7 – Nigeria
Vegetables
8 – Furniture 8 – Philippines
9 – Handicrafts 9 – South Africa
10 – Herbs and Spices 10 – Sri Lanka
11 – Hides and Skins 11 – Thailand
12 – Natural Products 12 – Uganda
for Cosmetics and
Pharmaceuticals
Applications
13 – Oilseeds 13 – Zimbabwe
14 – Processed Foods
and Sauces

The designations employed and the presentation of material in this paper do not imply the
expression of any opinion whatsoever on the part of the International Trade Centre
UNCTAD/WTO concerning the legal status of any country, territory, city or area or of its
authorities, or concerning the delineation of its frontiers or boundaries.

Mention of firms, products and product brands does not imply the endorsement of ITC.

Short extracts of this paper may be freely reproduced, with due acknowledgement of the
source. Permission should be requested for more extensive reproduction or translation. A
copy of the reprinted or translated material should be sent to ITC.
 TABLE OF CONTENTS

1 Structural Design Solutions ...................................................................................1

1.1 The Roles of Transport and Retail Packaging ...............................................1
1.2 Preparing the Product for Packing .................................................................2
1.3 Designing Packs to Minimize Product Damage ............................................2
1.4 Protecting Products from Moisture and Humidity.........................................4
1.5 Closing/Sealing of Packages..........................................................................5
1 Structural Design Solutions

1.1 The Roles of Transport and Retail Packaging

The main purpose of transport packaging is to minimize risks to a product during

storage, transport, and distribution. In its design careful consideration must therefore
be given to each stage in the product's distribution chain, to foresee and minimize the
risks involved. The transport package structure chosen must be suitable to withstand
all the hazards in the distribution chain, from point of origin to the point of its final
recovery or destruction. These hazards, and the transport packaging characteristics
needed to overcome them, are examined in detail in ITC's PACKit Transport
Packaging Cross-cutting Module.

The retail package functions relate mainly to the final stages of the distribution
process - delivery to the retailer and sale to the end user - and vary widely in terms of
handling and presentation requirements. Different countries have different traditions
and levels of development. No single package can satisfy all markets. When selecting
the type of retail package, remember that such packaging is first and foremost a
marketing tool and that its effectiveness depends on the correct choice for the market
concerned.

The challenge for the retail package designer is to be aware of the market sector being
targeted and to know its packaging requirements. Issues to consider include:

• Legal requirements of the importing market;

• environmental requirements;
• how distribution is organized;
• shelf-life required and sales estimates;
• space limitations;
• financial considerations;
• point of sale display function;
• reuse, recycling or disposal of packaging waste.

The exact relationship between the product and the packaging at the point of sale
should be decided. One of four scenarios may apply:
• Goods sold without packaging: shoes, clothes, and luggage. The retail package is
sometimes used by the purchaser of the goods after sale (e.g., shoe boxes);
• goods packaged for hygienic reasons: foodstuffs. Both the function of the package
and its selling role as must be considered;
• goods packaged to keep sets together: glasses, puzzles. The package must keep the
set (or an item and its accessories) together as well being attractive;
• goods using the package as showcase: jewellery, cosmetics. The pack's key feature
is its appearance; it often requires more design input than the product

All the above design considerations are normally specific to each market and/or market
niche, for every type of product. Some of their implications are examined in the following

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paragraphs.

1.2 Preparing the Product for Packing

The design of packaging for export should start by considering the preparation and
possibly adaptation of the product to be packed. This will entail:

• Ensuring that the product can be ready for packing free of dust, dirt or fingerprints.
It is especially important that fingerprints are removed from polished metal
surfaces, as they can lead to corrosion and staining;
• products that can be spoiled by humidity should be dry. Any paints, lacquers or
coatings on the product should also be completely dry before packing takes place;
• control systems should be in place to ensure that all parts of the product are present,
and that sets of articles are complete, etc., at the time of packing;
• identification stickers and other product labels should be available, correct and such
that their removal by the consumer does not damage the product.

Articles with delicate surfaces, such as polished metal, lacquerware, polished wood,
leather, etc., should be protected by wrapping with a soft material. The wrapping
material can be, for example, polyethylene film, tissue paper or cloth. Printing inks on
wrapping materials can permanently stain products.

1.3 Designing Packs to Minimize Product Damage

Protection against damage and breakage caused by normal transport stresses is especially
important for delicate products such as glassware or ceramics. Products that are not easily
broken, however, such as shoes, textiles and garments, should be prevented from moving
inside the pack. If they move, the package itself may be damaged and make the product
unsaleable even if it is in good condition. Broken or distorted packs are also more difficult
for the recipients to handle.

1.3.1 Immobilizing

Both transport and retail packs should be designed so that the products are not able to
move inside the pack during shipment. Products can be immobilized in several ways.
For many products, it may be enough to select the dimensions of the package so that
the products fill the package and leave no empty space (textiles, garments, etc.). For
some products detaching protruding parts may make transport packaging easier and
more economical.

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Figure 1: Size reductions can often be achieved without affecting pack
performance.

For boxes or folding cartons, special constructions may be used to hold products in
place and to separate them from each other.

Figure 2: Boxes designed to hold and separate their contents.

If specially constructed boxes are not available or are too expensive, it is possible to
use separate interior fitments to prevent product movement.

Figure 3: Interior fitment designed to protect and retain the product

Interior fitments can also contribute to the compression strength of boxes and cartons.

1.3.2 Cushioning

For fragile or easily damaged products, it is often necessary to use cushioning

materials. The cushioning specified should be used in sufficient quantity to ensure that
the product and cushioning material together completely fill the package, leaving little

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or no empty space. If the cushioning used absorbs moisture, as in the case of paper-
based materials or wood wool, it must be packed tightly enough to ensure that product
movement is prevented even when the material is damp.

1.3.3 Strengthening

For optimal strength of the product/package combination, the pack should be

completely filled. When there is no empty space, and provided the product itself can
support some of the load, the combination is normally much stronger than the package
alone.

If product size/shape variations and/or the available container dimensions preclude

completely filing the pack, the use of filling and strengthening materials should be
considered. Depending on the pack material, reinforcing pieces or fitments of
corrugated fibreboard, wood or plastic may be considered.

1.3.4 Unitizing and Palletizing

Unitizing, the consolidation of packs into a compact, secured load, and palletizing, the
consolidation of items on a pallet, can permit economies in terms of the specification
and cost of packs because pack strengths can safely be reduced, provided they are
always handled in this way. Unitized and palletized loads are often shrink-wrapped to
hold them together and to protect against moisture and pilferage.

1.4 Protecting Products from Moisture and Humidity

Warm and humid conditions are ideal for the growth of mould or mildew, which can
attack textiles, garments, leather, and all kinds of products made from natural fibres,
such as paper, sisal, straw or jute. Humidity also causes corrosion in some metals, and
may be the source of stains and discolouration in leather products.

During shipment from warm climates, temperature and humidity levels around the
package can change a lot even in a short time. This may lead to condensation both
outside and inside packages. Unless precautions are taken in designing and specifying
the pack, excellent conditions for mould growth and corrosion may be created.

There are several ways in which careful pack design and specification can minimize
moisture and humidity damage to products:

• Wherever practicable specify dry, impermeable packaging materials. Wood and

corrugated paperboard, for example, may contain high levels of moisture that can
be transferred to the products during transport to drier climates. Wooden packages
and materials should ideally have a moisture content of 12-14 %, never exceeding
20 %, and corrugated fiberboard boxes should have a moisture content not
exceeding 8-10 %.
• moisture sensitive products such as textiles, garments and leather products should
be dried just before packaging, and then be quickly packed in hermetically-sealed
plastic bags. The bags must have excellent moisture barrier properties, with good
seals and no pinholes,
• If storage and packaging in humid conditions cannot be avoided, consider the use of

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 ventilated packages. In this situation it may be desirable to employ package and
cushioning materials that can regulate humidity by absorbing it, for example paper
and corrugated fiberboard, or plastic packs with ventilation holes.
• for more expensive products consider the introduction of moisture absorbing agents
such as silica gel inside the package. If such absorbents are used, special attention
must be paid to the amount of absorbent needed for the product and package
concerned. The manufacturers of moisture absorbers provide instructions on the
correct quantity for a given product and pack size. As a rule, approximately 500
grams of absorbent is needed for an enclosed volume of 1 cubic metre, and the
package must be completely airtight;
• for corrodible metal machine parts, etc., there are papers and plastic films or bags
treated with a VPI (vapour phase inhibitor), which successfully absorbs humidity. As
these products can be expensive, their use is feasible only for relatively valuable
products.

1.5 Closing/Sealing of Packages

Correct and effective closing of packages can be just as important as their

construction and materials. Even a well-designed package will fail if it has not been
closed so that its seals are as strong or stronger than the rest of its structure.
Observations made throughout the distribution chain show that poor sealing is the
most common reason for package failure.

The most important closing methods and materials are gluing, taping, stapling/stitching,
strapping and heat sealing. In all cases, care is needed in the selection and specification of
sealing materials. Suitability for the package structure concerned and compatibility both
with the packaging materials and with the products must all be considered. Adhesives, in
particular, are subject to the same restrictions as packaging materials from the standpoints
of health, safety and contact with foodstuffs. Stapling and stitching with wire of, for
example, paper sacks, is discouraged both on safety grounds and because they may cause
material recovery problems