In an increasingly globalized and demanding world, packaging engineering has established itself as one of the fundamental pillars for ensuring a product’s success in the market. From the choice of materials to supply chain design, every aspect of the packaging process requires careful planning and specialized technical expertise. At the same time, consumer demands, sustainability awareness, and evolving regulations are constantly evolving in the field of packaging.
In this article we explore packaging engineering as a service, analyzing how specialized companies offer comprehensive solutions for the design, development, implementation, and continuous improvement of packaging systems. We also review current trends, key benefits, and how ATP-Packaging supports its customers at every stage of the process.
What is packaging engineering?
Packaging engineering is a technical discipline that combines engineering, industrial design, materials science, and marketing to develop packaging solutions that meet multiple objectives: protecting the product, communicating its value, complying with regulations, optimizing costs, and reducing environmental impact. Packaging engineers not only design the packaging but also ensure efficiency throughout the entire production process, from raw materials to the point of sale.
The scope of packaging engineering goes beyond the container itself. It involves a systemic view of the entire product lifecycle, encompassing production, logistics, storage, and the end-user experience. This makes packaging engineering key in sectors as varied as food and beverage, pharmaceuticals, cosmetics, hygiene, and any other field that requires customized packaging solutions.
Evolution and current trends
Packaging engineering has undergone significant evolution in recent decades. Some of the major trends include:
- Sustainability: Increasing use of recycled, biodegradable materials and processes that reduce the carbon footprint.
- Automation and Industry 4.0: Integration of robots and advanced control systems into packaging lines to maximize efficiency, obtain real-time data, and reduce errors.
- Smart Packaging: Incorporating sensors, RFID, or QR codes that allow product tracking, monitoring its status, and providing additional information to the consumer.
- User-centered design: : Search for the best user experience, facilitating the opening, handling and disposal of the packaging.
These trends reflect the growing complexity of the industry and the need for professionals and companies specialized in packaging engineering.
Basic principles of packaging engineering
Packaging functionality
Every container fulfills at least three essential functions:
- Protect the product: Avoid physical, chemical or biological damage that may affect the quality or integrity of the product.
- Communicate: Serve as an information and marketing support, including labeling, instructions for use and branding.
- Facilitate logistics: Allow efficient handling and transportation, optimizing space and ensuring product stability.
The balance of these three functions is the basis of packaging engineering. The packaging should be robust enough to protect, attractive to sell, and practical to handle.
Selection of materials
Selecting the material is one of the most critical steps. There are multiple options:
- Plastics (PET, PE, PP, PVC…): Lightness, resistance and high versatility.
- Paper and cardboard: Sustainable and easy to print, ideal for branding.
- Glass: Excellent barrier against gases and aromas, highly valued for premium products.
- Metals(aluminum, tinplate…): High durability and protection against light and oxygen.
The selection depends on factors such as product type, storage and transportation conditions, required shelf life, and the desired environmental impact.
Structural and graphic design
Packaging design encompasses both structural aspects, such as shapes, closures, dimensions and robustness, and graphic aspects, such as colours, typography, images and messages. Good structural design ensures product integrity during handling and transportation, while an attractive graphic design communicates brand identity and influences consumer choice.
Ergonomics and usability
Ergonomics is an often overlooked but highly important aspect. Packaging should be easy to handle, open, and close. Otherwise, it negatively affects the user experience. Similarly, in production and warehouse environments, packaging design should make staff tasks easier, reduce occupational risks, and increase efficiency.
¿Why is packaging engineering crucial?
Product protection
One of the primary objectives of packaging is to ensure that the product reaches the consumer in perfect condition. Packaging engineers consider transportation conditions, such as vibrations, impacts, and temperature changes; shelf life; and end-consumer usage. Poor design can result in claims, damaged products, and financial losses.
Cost optimization
Packaging that is too expensive can reduce profit margins, while packaging that is too weak can lead to higher losses due to damaged products. Packaging engineering seeks the optimal balance between cost and protection, analyzing variables such as:
- Material thickness
- Closure type
- Printing technologies
- Production processes
Through redesign and optimization, it is possible to reduce material usage, cutting production times and minimizing waste, generating substantial savings.
Regulatory and legal compliance
The packaging industry is subject to a wide range of regulations, especially in sectors such as food, pharmaceuticals, and chemicals. Packaging engineers must ensure that packaging complies with standards related to the food safety, the protection of sensitive substances, the correct labeling and the waste control failure to comply with these regulations may result in financial penalties and product recall.
Sustainability and environment
Concern for the environment is on the rise, and consumers are increasingly paying attention to the ecological impact of their purchases. Packaging engineering seeks to develop more sustainable solutions by reducing the carbon footprint and enhancing recyclability and biodegradability. This not only benefits the planet but also improves a brand’s reputation and fosters loyalty among an increasingly conscious audience.
Packaging engineering as a service: a comprehensive approach
The packaging engineering as a service involves delegating all stages of packaging development to external professionals—or a specialized team within the company itself. It’s a comprehensive approach that ranges from the initial needs analysis to the implementation of optimized machinery and production line solutions.
Scope and phases of the service
A comprehensive packaging engineering service typically includes:
- Consulting and diagnosis
- Design and prototyping
- Testing and validation
- Implementation and monitoring
Each phase provides specific value and is supported by the technical knowledge and experience of specialists in the field. Below, we delve into each of these stages.
1.- Consulting and diagnosis
The process begins with an analysis of the company’s current situation, taking into account factors such as:
- Product type and its protection requirements.
- Existing production processes.
- Current costs of materials and logistics.
- Branding and marketing needs.
- Regulatory and environmental challenges.
Based on this analysis, the packaging engineering team develops a comprehensive strategy for optimization. This includes recommendations for material selection, packaging redesign, and the potential integration of new machinery.
2.- Design and prototyping
Once the plan is defined, the creative and technical phase of the design begins. CAD tools and simulation software are used to develop virtual models, which are then translated into physical prototypes to validate design concepts. Feedback from all key parties (marketing, production, logistics, sales) is essential to ensure that the packaging meets both functional and strategic objectives.
4.- Testing and validation
Before launching the packaging into mass production, a series of performance tests are conducted, including:
- Compression tests to verify load resistance.
- Drop tests to simulate impacts during transport.
- Sealing and leaking evaluations to ensure tightness and protection.
- Stability and stacking tests to optimize storage and handling.
For food and pharmaceutical products, additional tests, such as substance migration and microbiological evaluations, are performed to certify packaging safety.
5.- Implementation and monitoring
The final phase consists of integrating the packaging solution into the production line, which may involve the purchase or modification of machinery, staff training, and the redefinition of logistics processes. Once implemented, monitoring is carried out to measure the effectiveness of the new design and correct any issues. Packaging engineering service does not end with the delivery of the project; rather, a collaboration is maintained for continuous improvement.
Machinery solutions and packaging lines
Packaging engineering is not only limited to the design of the container or package, but also involves the selection and configuration of the machinery suitable for producing them efficiently. This is where companies like ATP-Packaging. We stand out by offering complete packaging lines and automated systems that optimize production.
Automation of packaging lines
Automation increases productivity, improves the repetitiveness of processes and minimizes errors. Common solutions include:
- Automatic filling and sealing machines: Ideal for liquid, semi-solid or powdered products.
- Horizontal (flowpack) and vertical packaging machines: Designed to wrap products in flexible film, forming pillow-style bags, with or without side gussets. They are ideal for individual or grouped products in sectors such as food, pharmaceuticals, and consumer goods.
- Labelers: Precise label application.
- Vision inspection systems: To control quality and detect defects.
- Automatic packaging systems with robots and artificial vision: They optimize packaging precision and speed.
- Cartoning machines:To optimize the process of forming, loading and closing the cartons.
- Multi-format case packers: They allow products of different sizes or formats to be grouped and placed inside cases in an orderly and uniform manner, easily adapting to different configurations.
- Case and carton forming and closing machines: They automate the erection and sealing of cases or cartons, ensuring secure and durable packaging for transport and storage.
Robotics integration
Industrial robots play a key role in pick and place, palletizing, and product handling tasks. These systems increase production speed and reduce fatigue and occupational hazards for personnel.
Machinery customization
Every company has specific needs, so a standard machinery solution may not be sufficient. Packaging engineering as a service allows adapt machines and lines to specific requirements:
- Packaging dimensions
- Desired production speed
- Types of materials (e.g. plastic films, cardboard trays, etc.)
- Integration with traceability and ERP systems
Maintenance and continuous improvement
The efficiency of machinery depends on regular maintenance and technological upgrades. A comprehensive service includes preventive maintenance, the supply of spare parts and staff training to ensure smooth operation.
Success stories and applications in various sectors
Packaging engineering is applied to multiple industries, adapting to the specific requirements of each.
Chewing gum cartoning line
In this project, ATP-Packaging designed and installed an automated cartoning line for chewing gum, addressing challenges such as precise handling of small jars, production speed, and carton consistency. By replacing a manual process with an automated system, a continuous flow was achieved, minimizing downtime and ensuring consistency in every carton. Thanks to this solution, the client increased its production capacity and significantly optimized packaging efficiency.
Lid application line for wet wipes
ATP-Packaging collaborated with a hygiene product manufacturer to optimize their wet wipes packaging process. The solution included a lid applicator with a labeler and an advanced machine vision system. This solution enabled the client to increase production capacity, reduce defective products, and ensure package consistency and quality, strengthening its competitiveness in the market.
Praline picking line
In this project, ATP-Packaging developed a customized solution for a premium chocolate manufacturer requiring a delicate packaging process to preserve both the product’s integrity and its impeccable presentation. The system included five vision-guided picking robots that carefully identify, pick, and place each chocolate in its respective tray location, preventing damage or deformation. Synchronized sealing and labeling machines were also integrated, enabling higher production speeds and uniformity in the final packaging. Thanks to this implementation, the client was able to reduce waste, optimize time, and ensure that each chocolate reached the consumer with the highest quality.
See all success stories.
How can ATP-Packaging help you?
ATP-Packaging is a leading provider of packaging machinery and integrated packaging lines, delivering comprehensive, scalable solutions across a wide range of industries.
Know-how and specialization
The ATP-Packaging team has more than 25 years of experience in packaging engineering, covering projects ranging from initial consulting to the full implementation of automated lines. This specialization guarantees a professional approach and high-quality results.
Comprehensive services
ATP-Packaging’s featured services include:
- Personalized advice in the selection of packaging machinery and technologies.
- Design and adaptation of custom-made production lines.
- Preventive and corrective maintenance to ensure operational continuity.
- Employee training for the efficient use of equipment.
Accompaniment and training
Beyond installing machinery, ATP-Packaging provides continuous support for process optimization. This includes periodic audits, equipment upgrades, and staff training to make the most of available tools.
Packaging engineering as a service has become one of the most effective strategies for boosting companies’ competitiveness in a globalized market. Packaging engineers integrate knowledge of materials, technical design, ergonomics, sustainability, marketing, and regulations to offer tailored solutions that can mean the difference between a product’s success or failure.
Likewise, implementing automated packaging lines and innovating constantly in materials and technologies generates opportunities for cost optimization, time reduction, and improved user experience. To successfully carry out these projects, it is essential to have the support of specialized companies such as ATP-Packaging, that provide a comprehensive approach, from initial consulting to machinery installation and after-sales support.
