The Evolution of Industrial Packaging to Meet Modern Demands

New Materials and Designs Extend Product Shelf Life

As manufacturing and distribution networks grow more complex, protective Industrial Packaging must evolve to keep pace. Companies now ship components and finished goods greater distances through a wider variety of environments than ever before. These increasing demands posed new challenges that spurred the development of advanced packaging materials and designs.

An article posted just a few months ago in Plastics Today discussed how lightweight yet durable plastics like polypropylene copolymer (PPC) have replaced traditional corrugated for many applications. PPC resists moisture absorption better than paper-based materials while providing impact protection on par with rigid plastics. It also weighs significantly less, lowering freight costs. For electronics manufacturers in particular, PPC has become almost ubiquitous for shipping circuit boards and other sensitive components.

Another industrial packaging gaining popularity is expanded polyethylene (EPE). EPE foam cushioning fills irregularly shaped voids better than other types of void fill like shredded paper or plastic cushioning made from recycledcontent. It is 100% recyclable through store drop-off programs. EPE protects without adding excessive weight compared to alternatives. Leading electronics, appliance, and automotive manufacturers now specify EPE-filled containers for many shipping applications.

Custom container designs now integrate multi-layer protection tailored to each product's durability needs. Roofing material shipments, for example, require protection from rain, dust, and accidental impacts during transport and staging. Many producers work with industrial packaging engineers to develop roofing product containers with a weather-resistant paper or plastic outer layer, corrugated interior stiffeners, and void-fill pockets containing moisture-absorbing desiccants. The containers withstand exposure to weather for prolonged periods if left outside.

Other product categories push packaging design beyond simple containment. Medical devices and pharmaceuticals demand industrial packaging that maintains extremely tight temperature and humidity control during shipping. Some use passive cooling techniques like phase-change materials incorporated into interior cushioning layers. Others integrate active heating and cooling technologies powered by renewable energy sources. Ensuring product integrity from factory to final destination remains a top priority.

As time-in-transit increases, so does the potential for damage. That's why more industrial packaging designers implement ruggedization techniques proven successful in military applications. Strategically placed reinforcement strapping helps containers better resist crushing and prevent bowing of sides. Hard plastic exteriors and impact-absorbing interiors provide drop-test certification exceeding typical distribution handling requirements. The added durability reduces replacement freight and storage costs from damaged shipments.

Global supply chains introduce new concerns beyond the packaging itself. Stricter regulations aim to curb the environmental impacts of all distribution network activities. As a result, many companies prioritize using recycledcontent and recyclable/compostable packaging materials. They also optimize packaging sizes to utilize transport space more efficiently. Some evaluate opportunities to consolidate smaller shipments or utilize backhauls to balance loads. Despite inherent complexities, sustainable practices benefit both the environment and the bottom line over the long run.

As the pace of technology and globalization increases, Industrial Packaging design continues to progress. Innovations in materials, engineering, configuration, and sustainability advance distribution networks' ability to protect products and optimize efficiency. With collaboration between manufacturers, distributors, and packaging engineers, protective solutions can overcome modern challenges while supporting worldwide commerce. The evolution of Industrial Packaging remains inextricably tied to manufacturing and business success in tomorrow's connected world.