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Topic: Custom Design & Production

Industrial packaging designed around the product and process

Industrial packaging needs to accommodate more than just a product’s dimensions. Factors such as fragility, transport loads, the operating environment and handling requirements all help determine the necessary construction, materials and interior components.

On this topic page, we explain when standard packaging is not sufficient, which choices are critical to protection and ease of use, and how Faes turns a packaging challenge into a design, a prototype and a production-ready solution.

Why This Topic Matters

Packaging that fits doesn't automatically provide adequate protection

A standard case or crate may appear suitable in terms of dimensions, while failing to adequately address what actually happens to the product during transport and use. Weight, fragility, shocks, vibrations, environmental conditions and the way the product is secured all determine the level of protection required.

It's not just about preventing damage. Choosing the wrong packaging can also result in unnecessary volume and weight, difficult handling and higher costs throughout its lifecycle. That's why effective industrial packaging starts with the product and the process, not with the type of case or crate.

Protection requires more than a sturdy exterior

During transport, shocks and vibrations can be transferred to the product through the packaging. The construction, interior and securing methods must therefore work together and be tailored to the product's fragility and the stresses it encounters during transport.

Unnecessarily large or heavy packaging takes up valuable space

Standard sizes may require more volume or material than technically necessary. This affects storage, transport, stackability and handling. By considering both the product and logistics from the outset, packaging can be designed more efficiently and purposefully.

Packaging must fit the workflow

A product is not only transported but also lifted, opened, unpacked, inspected and repacked. The positioning of components, accessibility, weight and ergonomics therefore play an important role in determining how well a packaging solution works in practice.

Late design decisions lead to additional work

When requirements for protection, production or testing only become clear at a late stage, the design may need to be revised. By defining these requirements early on, the construction, materials and interior can be developed from the outset with production and any necessary validation in mind.

Why Faes?

Years of packaging expertise

140

Packaging People with the expertise to solve your packaging challenges

1.000+

B2B customers, including in Defence, High-Tech & Medical

Steps from initial consultation to final solution

Expertise in:

Engineering
Interiors
Packaging Testing
Materials
Cleanroom

Frequently Asked Questions About Custom Design & Production

Custom packaging becomes relevant when standard packaging does not adequately meet the requirements of the product or the way it is transported and used. Examples include unusual dimensions, fragile components, specific transport stresses or requirements relating to handling, cleanliness and protection.

This does not mean that the entire packaging solution always needs to be designed from scratch. Sometimes, a standard case with a custom interior is sufficient. The application determines which solution is needed.

Want to learn more? Read about the differences between standard and custom packaging solutions

Want to know whether a standard solution is sufficient for your product? Discuss your packaging challenge with our experts.

A good design starts with clearly defined requirements. In addition to dimensions and weight, important factors include fragility, transport methods, operating environment, handling, storage and any applicable standards or customer requirements.

By documenting this information in a requirements specification beforehand, the construction, interior and material selection can all be based on the same principles from the outset.

Want to learn more? Read how to create a requirements specification for your custom packaging

Haven’t fully identified all your requirements yet? Let us help you define the starting points for your design.

There is no single material that is the best choice for every application. Weight, fragility, transport frequency, weather conditions, cleanability, lifespan and logistical requirements determine which materials and construction are most suitable.

Material selection is therefore not considered separately from the overall design. The interior, the way the product is secured and the entire transport route also play a role in this decision.

Want to learn more? Read how to choose the best transport packaging for your product

Unsure which materials or construction methods to choose? Ask our packaging experts for material advice.

A strong outer packaging alone is not enough. The product must also be properly supported and secured to limit movement and absorb the stresses encountered during transport in a controlled manner.

When designing a custom interior, factors such as weight, geometry, vulnerable areas and transport stresses are taken into account. Depending on the application, prototype and transport testing may then be necessary to further evaluate the design.

Want to learn more? Read how foam interiors protect sensitive equipment

Want to know how your sensitive product should be supported? Let us assess your product and transport risks.

Cleanroom packaging is not automatically required simply because a product will eventually be used in a cleanroom. Important considerations include whether the packaging itself enters the controlled environment and which cleanliness and material requirements the customer specifies.

When this is the case, these requirements directly influence material selection, construction, cleanability and the packaging process. Cleanroom requirements must therefore be clearly defined during the design phase.

Want to learn more? Read when cleanroom packaging is necessary

Does your product need to be delivered under clean conditions? Discuss your cleanroom and packaging requirements with our specialists.

This theme contains 60 Articles , 3 Keynotes and 3 Whitepapers

Articles (60) Keynotes (3) Whitepapers (3)

Uitgelicht

Whitepapers

Whitepaper: Packaging as an Engineering Challenge

Shipping damage to high-tech products is rarely just bad luck: it is the predictable result of packaging choices made without sufficient knowledge. In this white paper, Faes explains why packaging is not a minor logistical issue, but an engineering challenge with measurable risks.

Download whitepaper

Whitepapers

Whitepaper: Customisation for demanding environments

This white paper demonstrates how customised packaging provides protection in the most demanding environments. With a focus on strict standards, sustainability, and first-time-right solutions, you will discover how packaging contributes to safety and efficiency.

Download whitepaper

Whitepapers

Proper packaging according to cleanroom standards

Cleanroom packaging requires strict compliance with standards to prevent contamination. Faes assists companies in making the right packaging choices and offers expertise and solutions that meet the highest cleanroom requirements.

Download whitepaper

Topic: Custom Design & Production

Industrial packaging designed around the product and process

Why This Topic Matters

Packaging that fits doesn't automatically provide adequate protection

Why Faes?

Expertise in:

Frequently Asked Questions About Custom Design & Production

When do I need custom packaging?

What information is needed to design custom packaging?

Which material is suitable for my industrial packaging?

How do you protect sensitive equipment against shocks and vibrations?

When is cleanroom packaging necessary?

Uitgelicht

Whitepaper: Packaging as an Engineering Challenge

Whitepaper: Customisation for demanding environments

Proper packaging according to cleanroom standards

All articles

How do you prevent corrosion in military packaging in humid conditions?

How do you adapt defense packaging for different climate zones?

Why do defense organizations choose certified defense packaging?

IP65, IP67 or IP68: which IP rating is required for military packaging?

Custom military packaging: from design to certified production

How does MIL-STD packaging differ for air versus sea transport?

How do tactical cases protect sensitive defense electronics?

What is industrial custom packaging?

How does a drop test for cases and boxes work?

How do you optimize case design for stackable storage?

How are foam interiors designed for optimal protection?

Which hinge mechanisms are the most reliable for heavy duty use?

Plastic welding: the next step in strong, reliable customised packaging

Which sterilization methods are suitable for medical transport cases?

Which corrosion resistance tests are mandatory for seawater transport?

How do you safely transport lab specimens in controlled temperature?

What are flight cases for defense equipment?

What are medical packaging?

When is wooden packaging better than plastic?

How can you adapt packaging to different product loads?

How do you prevent EMP damage to military equipment during transport?

How does a temperature test work for packaging that has to withstand extreme temperatures?

How is a vibration test performed for industrial packaging?

How does an IP test for dust and waterproofness of packaging work?

How do you protect vulnerable field equipment on construction sites?

What are defense packaging solutions?

What is the difference between civilian and military packaging?

How does military packaging work under extreme conditions?

How to choose the right packaging solution for defense equipment?

Why 3D scanning is essential for perfectly fitting packaging

How does packaging for fragile products work?

What is industrial packaging?

What is the difference between standard and custom packaging?

How are medical packages tested for safety?

How are medical packages designed for transport?

What are the benefits of system integration?

EPP Packaging: The ideal solution for the medical supply chain

Points to consider when purchasing (industrial) packaging

ESD safe case: what to look out for

What is the best time to start packaging development?

What does packaging have to do with SLAs?

Here’s how to create a set of requirements for your custom packaging

An incomplete set of requirements for your packaging: these are the consequences

Considerations for equipment disposal at Defense

The EPP case: surprisingly versatile

5 concerns when shipping medical devices

So important is your set of requirements for the best custom packaging

Here’s how to create a test plan for Defense

Faes wraps F-16 vertical tail on site

Skipping the prototype phase: new trend in product development?

The challenges of clean packaging

Here’s how to ensure modern equipment remains deployable on missions

Why is early involvement so important?

Is cleanroom packaging necessary?

Infographic: The possibilities of system integration

Checklist: what to look out for in System Integration?

What is system integration?

How do I choose the best transport packaging for my product?

4 pitfalls in the development of industrial packaging

Packaging specialist as a partner in a Defense procurement process

What We See in Practice

When is standard packaging no longer sufficient?

How do you design packaging for repeated use?