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Prototyping in packaging design plays a crucial role as it allows for the practical testing and validation of design concepts before full production. This process helps identify potential flaws, assess functionality, and gauge customer responses. By prototyping, designers can make informed adjustments, leading to more effective and appealing packaging solutions, ultimately saving time, and resources, and enhancing customer satisfaction.

Before diving into the role of prototyping, let’s briefly explore the demographic interests that influence packaging design in the American market. With a diverse consumer base, the United States showcases varying preferences and values. Research reveals that sustainable, eco-friendly packaging resonates particularly well with environmentally conscious millennials and Gen Z consumers. Moreover, the emphasis on convenience, aesthetics, and product information appeals to all age groups.

The Role of Prototyping:

Prototyping is an integral stage in packaging design that bridges the gap between conceptualization and production. It’s a tangible manifestation of ideas, enabling designers and stakeholders to assess various aspects before finalizing the design. Let’s explore the key dimensions in which prototyping proves invaluable:

Visual Assessment: A prototype allows designers to visualize how the packaging will look and feel in reality. This visual representation aids in identifying design flaws, ensuring that the final product aligns with brand identity and resonates with the target audience.
Functionality Testing: Beyond aesthetics, prototypes enable rigorous testing of functionality. This includes evaluating aspects like ease of opening, closing, and storage. Iterative prototyping ensures that packaging is not just visually appealing but also user-friendly.
Material Selection: Prototyping aids in selecting the most suitable materials for the packaging. Through experimentation, designers can assess factors like durability, eco-friendliness, and cost-effectiveness, aligning with both consumer demands and brand values.

A Brief Guide to Prototyping:

Here’s a concise guide to the prototyping process in packaging design:

Conceptualization: Begin with a clear concept of the packaging design, considering both aesthetic and functional elements

Sketching: Translate your concept into rough sketches, exploring different layout options and visual elements.

Digital Prototyping: Utilize design software to create digital prototypes. This step helps refine the design before moving to physical prototypes.

3D Printing: Embrace the power of 3D printing to create tangible prototypes. This allows for a tactile assessment of the design and its functionality.

Testing and Iteration: Test the physical prototype for usability, visual appeal, and any potential shortcomings. Iterate on the design based on feedback.

Prototyping in packaging design a transition to packaging testing:

In the realm of packaging design, several crucial tests need to be conducted to ensure the safety, functionality, and appeal of the packaging. These tests help identify potential issues, assess the packaging’s performance under real-world conditions, and ensure compliance with industry standards. Here are some essential packaging tests:

Drop Test:

Description: This test simulates the impact of a package being dropped during handling or transit. It assesses the package’s ability to withstand shocks and protect the contents.
Equipment: Drop test machines, which elevate and release packages onto hard surfaces from predetermined heights.
Procedure: Packages are secured to the drop test apparatus and released multiple times from varying heights. The package’s condition and the contents’ integrity are examined.
Standards: EN 15552 Packaging, ASTM D4169, ASTM D7386
ISTA procedures 1A, B, C, D, G, H / 2A, B, C / 3A, B, E, F, H, K / 4 series / 6-Fedex; 6-Amazon.com.​
MIL-STD-810G and MIL-STD 202 Random Drop US Military Standard.

Technical specifications

  • 2 different designs depending on the packaging size
  • Drop height up to 2m
  • Steel impact surface
  • Intuitive touch screen controller
  • Hydraulic dumpers to reduce noise
  • Maximum load up to 1500kg/ 3306lbs.
  • Guaranteed repeatability.
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Compression Test:

Description: Evaluates how well a package holds up under vertical pressure, mimicking stacking during shipping and storage.
Equipment: Compression testing machines with load cells and adjustable platforms.
Procedure: Packages are placed on the compression machine’s platform, which is then compressed at a controlled rate. The load at which the package fails or deforms is noted.
Standards: EN 15552 Packaging, ASTM D4169
ISTA procedures 1A, B, C, D, G, H / 2A, B, C / 3A, B, E, F, H, K / 4 series / 6-Fedex; 6-Amazon.com.​
MIL-STD-810, ISO 8611, JIS Z 0202, JIS Z 0234.

Technical specifications

  • The electric machine is controlled by a state-of-the-art, high-precision electric servomotor, which allows the machine to be maneuvered in a more efficient and cleaner way.
  • Transmission is carried out by means of spindles to reduce noise and increase precision.
  • Heavy-strength compression plates
  • Maximum compression forces up to 200 kN
  • Stroke up to 2400 mm
  • Testing tables in different sizes
  • Variable compression speed: 5-200 mm/min
  • Load accuracy <0.5%
  • Position accuracy: <0.1 mm
  • Testing data on-site
  • Intuitive controller
  • Automatic report generator
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Vibration Test:

Description: Replicates vibrations experienced during transportation, identifying potential design weaknesses.
Equipment: Vibration tables or shakers that produce controlled vibrations.
Procedure: Packages are secured to the vibration equipment, which applies various frequency and amplitude settings. The package’s performance and content integrity are evaluated.
Standards: EN 15552 Packaging, ASTM D4169, ASTM D7386
ISTA procedures 1A, B, C, D, G, H / 2A, B, C / 3A, B, E, F, H, K / 4 series / 6-Fedex; 6-Amazon.com.​

Technical specifications

Different possibilities and combinations:

  • Vertical Vibration Test System
  • Vertical Vibration + Pitch & Roll System
  • Pitch & Roll Module
  • Rotational Vibration Testing System
  • Motovibration Testing System
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Impact Test:

Description: Mimics the entire journey of the package to identify vulnerabilities.
Equipment: Various testing machines that replicate transportation conditions (e.g., incline impact testers, horizontal impact testers).
Procedure: The package is subjected to a series of tests that simulate handling, stacking, transportation, and storage conditions.
Standards: EN 15552 Packaging, ASTM D4169, ASTM D7386
ISTA procedures 1A, B, C, D, G, H / 2A, B, C / 3A, B, E, F, H, K / 4 series / 6-Fedex; 6-Amazon.com.​

Technical specifications

Different possibilities and combinations:

  • Inclined Impact Tester
  • Horizontal Impact Tester
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Leverging prototyping in packaging design: innovative machinery

Data loggers

Accurate Data Collection: Data loggers are instrumental in collecting accurate and real-time data during packaging tests. They continuously record parameters such as temperature, humidity, pressure, and vibrations, providing a comprehensive view of the packaging’s performance.
Critical Insight: Precise data allows testers to identify potential issues and vulnerabilities in packaging design. This insight aids in making informed decisions about design improvements, material choices, and adjustments needed to enhance packaging performance.
Documentation and Compliance: Data loggers provide a verifiable record of testing conditions and results. This documentation is essential for compliance with industry standards and regulations, ensuring that the packaging meets the necessary quality and safety requirements.

Technical specifications

  • High-performance primary capacitive triaxial accelerometer up to 40G for acceleration measurements with sampling frequency up to 4000 Hz.
  • High-performance secondary piezoresistive triaxial accelerometer up to 2,000 G for shock measurements with sampling rates up to 20,000 Hz.
  • Pressure, humidity, and temperature sensors
  • Gyroscope (to measure tilt and speed change in Pitch, Rall, and Yaw).
  • Magnetometer.
  • Generates an automatic report, profile, and charts.
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Measuring Vision Systems

Perks of our innVision

Increased Efficiency: Vision measurement systems expedite analysis compared to manual methods.
Enhanced Reliability: They provide more dependable results due to automation and precision.
Time Savings: Reduces analysis time, freeing up time for other crucial tasks.
Accuracy and Detail: Offers precise measurements and detailed analysis, minimizing errors.
Competitive Improvement: Drives productivity and quality, providing a competitive edge in the market.

Technical specifications

  • High-speed cameras

We offer companies high-speed cameras to record load deformation second by second. After the analysis of the images, it is possible to see the deformation of the load unit frame by frame and generate a video to visualize the complete test.

  • High-tech software

The software of the innVision solutions is capable of analyzing the deformation in real-time, generating an automatic report with photos and videos, which show the deformation of the load unit at each moment.

  • Reliable results

innVision solutions have been created to help companies optimize unit loads. Therefore, they can be used to perform their own quality control tests, to measure load stability, or to comply with main test procedures or standards, such as EUMOS 40509.

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