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Summary of this article

An incomplete packaging requirements specification rarely results only in a less suitable packaging solution. Its consequences become visible throughout the entire supply chain, ranging from damaged products and additional handling to higher transport costs, production delays and customer dissatisfaction. When requirements relating to protection, storage, transport, ease of use and internal processes are not fully defined in advance, the packaging is designed on the basis of assumptions. As a result, errors often come to light only after production, logistics or delivery processes have already begun.

The financial impact extends beyond the cost of new or modified packaging. Inadequate protection can lead to returns, repairs, replacement products and additional administrative work. Inefficient dimensions increase the use of space in storage and transport, while packaging that does not align properly with the production process creates additional handling and lost time. Delays, damaged deliveries and an unprofessional appearance can also undermine customer confidence, potentially resulting in negative reviews, lost revenue and reputational damage.

For management, this means that a requirements specification should not be treated solely as a technical product specification, but as a shared supply-chain document. Product characteristics, logistics conditions, applicable standards, internal work processes and end-user expectations must be collected and validated in advance with all relevant departments. Supporting this process with a standard checklist, clear documentation and specialist packaging expertise creates a complete and verifiable basis for development. This limits the need for subsequent adjustments and turns packaging into a manageable instrument for controlling costs, quality, productivity and customer satisfaction.
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And how do you ensure that your set of requirements is indeed complete?

In a previous blog, I talked about the importance of having a set of requirements when developing custom packaging. In this blog, I tell you about what the consequences can be when you have packaging developed based on an incomplete requirements package. And what you can do to avoid this.

If you don’t pay enough attention to putting together your package of requirements, the prerequisites and assumptions may not be right. As a result, the final packaging may not be satisfactory. And if your packaging is not optimal, this can lead to damage. Damage to your product or in the form of unnecessarily high costs for transport and storage. But image damage is also a serious risk if you repeatedly fail to deliver your product undamaged to the customer.

Below I further explain three key risks:

Een medewerker gebruikt een vorkheftruck om een pallet met kartonnen dozen te laden in een vrachtwagen, met hulp van het StackAssist-systeem. De pallets zijn strak verpakt voor transport, wat zorgt voor maximale veiligheid en efficiëntie.

1. Higher costs

Packaging that does not meet the required standards can lead to higher costs in several ways. Examples include:

  • The packaging provides insufficient protection, causing products to be damaged regularly during transport. The product then has to be returned and delivered again, resulting in additional costs for transport, administration and handling.
  • The packaging takes up unnecessary space during transport and storage because its dimensions fall outside standard limits, its shape is inefficient or it contains too much unused space.
  • Packaging that is not properly designed can significantly shorten the service life of equipment or tools.

2. Image damage and lost sales

You may not immediately think of this, but delivering packaging that isn’t optimal can put a big dent in your corporate image. Consider:

  • Frustrations due to products that keep arriving defective(read more about Defect On Arrival here);
  • Packaging that is not representative;
  • Packaging that is awkward or contains a lot of air;
  • Packaging that has a shorter lifespan than its contents (e.g., tools);
  • Packaging that is not sustainable (companies are increasingly alert to this).

3. Lower productivity

Your project could be seriously delayed if the packaging turns out to be inadequate. If you do take the packaging into use, it will affect your company’s productivity. Packaging that does not meet all logistical requirements or that delays operations is inefficient. For example, because packing and unpacking takes an unnecessary amount of time. So it is important to consider in your set of requirements all the links in your supply chain and how productivity is affected by the packaging.

How come your set of requirements is incomplete?

There are several causes, including time pressure, insufficient preparation, interim changes, inadequate information and lack of knowledge. What is often behind this is that the importance of a set of requirements in advance is quite underestimated.

Lack of time

The product is almost ready, the product deadline is approaching. Now all that remains is packaging! There is no time for details and halting the project for the packaging is not an option. Time pressure then leads to concessions and a less successful end result.

Changes in product development

It happens regularly that things change during the product development process. But unfortunately, it also happens regularly that those changes do not make it into the requirements package. This can have major consequences. Of course it is important that the packaging meets the correct specifications.

Insufficient details

In outline, the package of requirements states what the packaging must meet, but the descriptions are not sufficiently concrete or detailed. For example, a maximum weight is stated, but it is unclear whether this is inclusive or exclusive of the product. Inadequate information or information that can be interpreted in multiple ways can lead to wrong choices in packaging development.

Insufficient understanding of the requirements and desires of all users

It’s not always feasible to involve all users of the packaging when you’re drawing up the requirements package. Or to fully visualize the route the packaging will take in the supply chain. Then it is not sufficiently clear what risks the packaging will encounter along the way.

Too little knowledge of packaging

Knowledge of packaging materials is indispensable to properly translate the package of requirements into the right packaging solution. Too often it turns out that choices made are not feasible in practice. For example, because of the properties of the chosen material. The packaging turns out not to protect the product as well as hoped in these circumstances. Only then does it become clear that packaging is a profession in itself.

How do you avoid an incomplete set of requirements?

  • Start on time and give the requirements package the attention it deserves. Make sure you have space to gather input from users. Starting on time also allows you to make adjustments if the product specifications change in the interim.
  • Keep an eye on the details. Keep on asking until you have all the points of interest clear.
  • Furthermore, of course, it helps to use a specialist who is knowledgeable. My colleagues and I are happy to help you draw up a thorough set of requirements so that you actually get a packaging solution that fully meets your requirements and wishes.

Getting started on your requirements package? Here’s how to tackle it!

Do you have a question for us? Leave it in the form below or contact us directly.

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Harold Pijs

Harold Pijs

Customer Service Manager

Harold Pijs has been with Faes for more than 30 years and is Manager of Customer Service. As the driving force behind inside sales, he ensures reliable customer communication and a smooth order process. His experience makes him an indispensable link in customer-oriented service.

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