Special packaging
When a product is heavy, irregular or fragile, standard formats rarely solve the problem. Then the work starts in the structure rather than in a catalogue.
Common starting points
- Products with protruding parts that need their own cavities.
- Heavy products where base and corners must be reinforced.
- Multi-part sets that must stay separated.
- Long or narrow formats that do not survive normal handling.
The engineering work
We start from the product's dimensions, weight and vulnerable points, produce a dieline and build a physical mock-up. The mock-up is tested with the real product, adjusted and approved before tooling is made. For heavier products, corrugated is often combined with board inserts or a timber frame, depending on transport mode.
Transport and regulations
Transport mode shapes the structure: sea freight means moisture and long transit, air freight means weight and volume limits, groupage means more handling points. Some products are subject to specific requirements, for example when exporting timber materials. We raise such questions early and verify them with supplier and forwarder.
Conditions
- MOQ varies more than for standard formats and is set per project.
- Lead time normally 6-8 weeks after confirmed design, often longer with tooling.
- A physical sample is in practice necessary for special structures.
Material, structure and finish in detail
We review board quality, thickness, fit, print technique and finishing with you and turn it into a specification a supplier can produce against.
FAQ
Frequently asked questions
- Can you start from an existing pack?
- Yes. Often the fastest route is to analyse where today's packaging fails and fix exactly that.
- How is protection tested?
- With physical samples and, where needed, drop or vibration testing at a supplier or test institute.
- Is special packaging always more expensive?
- Per unit often yes, but fewer transport damages and lower volumetric weight can reduce total cost.
- Who manufactures the structure?
- Selected suppliers. VyPack is responsible for engineering, specification, quality control and project management.
Related pages
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