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Pack Design February

03 febr. 2022 —
Reusable packaging

Pack Design February

Pack Design February

The client’s challenge

The client manufactures two kinds of custom-made truck lights (one round and one rectangular), which are shipped to an external finisher before being returned and placed into storage. To avoid damage to the reflector, the lights can only be touched at designated points, which proved a challenge when packing them for transit.


Prior to contracting Antalis, the lights were packed into polyethylene bags and then placed in layers into a box. Unsurprisingly, damages were high, around 30-40%. The client approached Antalis to help them find a packaging solution that would provide adequate protection while ensuring minimum contact.

The Antalis solution

Bespoke packaging design comprising laser-cut foam and a corrugated board outer carton.



1. Cut foam securely and safely holds several round lights, making contact only with the safe touchpoints.




2. Making contact only with the designated touchpoints, a foam base layer supports the lamps while the top layer provides further protection.


3. Five layers of the lamps are packed into the bespoke outer carton.









Alan Stanley
Account manager at Antalis Packaging

« This was a complex design brief. Coming up with a packaging design that would provide sufficient protection while using minimum touchpoints was a real challenge for the design team at the Antalis Smart Packaging Centre, but there is no doubt that they were equal to the task. The client was delighted with the result, especially with the fact that the packaging is reusable, with helps to further improve their environmental footprint. »

The process

Using a clear framework, the Antalis packaging team set to work developing a solution:


  • Explore: A site visit was carried out to gain a clear understanding of the challenges faced and of the scope and scale of the requirement.The two lights, one long and rectangular and one round, can only be touched at specific points to avoid damage or they won’t work properly. It was therefore important that any new packaging proposed would provide optimum protection with minimum contact. Samples were taken back to the Antalis Smart Packaging Centre to help in the design and prototype phase.
  • Propose: Reusable packaging inserts made from a reusable, strong and hardwearing foam that bounces back into shape. For the rectangular light, foam was cut to fit the touchpoints, providing protection to the top and bottom of the light with minimal contact. The round lamps are packed into a foam tray with circular columns that securely hold and support the lamps from underneath. All lights are then packed in layers in a bespoke corrugated box.
  • Test: The prototype was tested successfully and the client delighted with the result.

Advantages of the solution



Reduced packing time.



Reusable material resulting in minimal use of materials and waste. Reduction of damages.



Less material used, reduction in product damages and reduction of delivery costs.

Services provided

Smart Consult


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We help you optimise your costs and packaging process efficiency.

Smart Tech Design




We create bespoke, high-tech solutions to meet any of your specific challenges.