Case Study in cost optimization for glass manufacturer

Client Overview

A leading glass bottle manufacturer faced high packaging and logistics costs due to inefficient box designs. Their existing packaging did not maximize pallet utilization, leading to wasted space, higher transportation costs, and increased material expenses.

Challenges

1. Suboptimal Box Dimensions – The packaging was not aligned with standard pallet sizes, leading to inefficient stacking.

2. Excess Material Usage – The existing box design used more corrugated material than necessary, increasing costs.

3. Frequent Transit Damage – The current packaging design did not provide optimal protection, increasing breakage rates.

4. High Freight Costs – Inefficient stacking meant more pallets were required, increasing shipping costs per unit.

Our Approach

1. Packaging Redesign for Optimal Fit – We analyzed the client’s pallet dimensions and redesigned the box to fit perfectly on a standard pallet, reducing empty space.

2. Material Optimization – By modifying the die-cut design, we reduced unnecessary corrugated layers while maintaining structural integrity.

3. Strength Testing & Prototyping – Conducted compression tests and drop tests to ensure the new design provided the necessary protection.

4. Improved Stackability – The optimized design allowed for 30% more bottles per pallet, reducing the number of shipments needed.

5. Implementation & Cost Reduction – The new design was rolled out across all packaging, streamlining production and logistics.

Results & Impact

✅ Annual Savings of INR 50 Lakh – Reduced material usage and optimized shipping efficiency.

✅ 20% Reduction in Freight Costs – Fewer pallets were needed per shipment, lowering transportation expenses.

✅ 30% More Bottles Per Pallet – Maximized space utilization, improving warehouse storage and shipping efficiency.

✅ Lower Breakage Rate – Improved protection led to a 15% decrease in transit damages.

Conclusion

By optimizing the packaging design, we helped the glass bottle manufacturer significantly reduce costs while improving storage and transportation efficiency. This project highlights how strategic packaging solutions can drive both cost savings and operational efficiency.

👉 We specialize in designing customized corrugated packaging solutions to optimize cost, reduce waste, and enhance protection for manufacturers across industries.