The Challenge
A global manufacturer of powdered beverage products wanted to better understand the lightweighting potential across its carton packaging portfolio.
The client was looking to establish strategic weight reduction targets for its packaging development teams, while ensuring any proposed changes remained compatible with existing operational capabilities.
ThePackHub was tasked with investigating how much material could realistically be removed from folding boxboard cartons without compromising functionality or how they would be constructed.
Our Approach
ThePackHub conducted a detailed structural assessment across the client’s carton portfolio, identifying approximately 20 carton formats. These were then grouped into common packaging families based on shared keyline structures.
Each format was evaluated holistically, considering:
- Material utilisation
- Sheet utilisation
- Gauge of the sheet
- Opening features
- Flaps, panels and overlaps
The project explored not only opportunities to reduce board weight, but also alternative structural approaches that could improve sheet layout efficiency and overall material usage.
Weight reduction opportunities were quantified across each carton family, alongside practical design recommendations that aligned with the client’s existing operational setup.
The Impact
The project gave the client the confidence to establish measurable lightweighting targets across its packaging portfolio, including opportunities for up to 30% material reduction on selected lines and approximately 20% average reduction overall.
Alongside quantified lightweighting potential, ThePackHub provided multiple strategic approaches for reducing material usage, improving sustainability performance in line with PPWR requirements and lowering associated packaging costs and EPR fees.
The work helped the client pursue achievable material reduction opportunities without disrupting existing production capabilities.