This project involved the structural packaging engineering and logistics design for a premium, three-flavor ketchup lineup packaged in elegant glass bottles. Developed specifically for high-volume warehouse environments like Costco, the packaging layout balances consumer bulk value with a sophisticated, restaurant-grade aesthetic suitable for direct tabletop display. To withstand the rigorous retail supply chain, the packaging employs a rigid multi-tier material strategy. Individual three-pack bundles are constructed with a durable 32 ECT board weight to protect the glass from impact, and these units are nested into heavy-duty 40B flute corrugated trays that hold eight multi-packs each for a total of twenty-four bottles per tray. To streamline the client’s manufacturing operations, the three-pack carrier features an innovative design with two outer windows that open during the packing process. This structural feature allows for precise mechanical loading while ensuring the glass bottles do not rub against one another, successfully eliminating the risk of surface friction or unnecessary breakage on the line.
The primary logistics challenge was designing a high-efficiency pallet configuration capable of supporting the massive top-load weight of double-stacked pallets during transit. To optimize both freight and warehouse operations, structural assets were designed in ArtiosCAD, while the overall pallet pattern and cube utilization were perfected using TOPS software. The final layout features a four-way shoppable configuration that allows customers to effortlessly view and pick products from any side of the display without any initial unboxing. The load is fully secured using high-tension cling wrap and corner boards, and it incorporates 32B flute slip sheets between layers to meet standard club-store guidelines for easy stock replenishment.
