End to end development of packaging development | Milk-based product format

Refill packaging

End to end development of packaging development

Milk-based product format

BRIEF TO PACKFORA ​

Execute End to End Packaging development including the filling machinery and packaging documentation.

Packaging Procurement

01

Identification of right quality vendors for each of the packaging BOM.

02

Advisory on "should cost model", provide choice of vendors for competitive bidding.

03

Supporting the procurement function for negotiation via techno-commercial inputs.

Packaging Lines

01

Identification of right quality suppliers as per product and packaging needs

02

Defining technical specifications for machinery.

03

Placement of 5 vendors for each product format for competitive bidding.

04

Strategic advice on shortlisting and order placement

05

Packaging line qualification and process validation.

Packaging Development

Packaging Design for Bottle, Cup, Lidding film, Lid, Intermediate packaging and Secondary packaging.

Building design for right cost efficiencies for manufacturing.

Choice of right technology of manufacturing for given packaging material.

Identification of right material specifications and structures.

Development of Mold, Printing Cylinders / Stereos

Development of qualification protocols for each packaging BOM.

Qualification of molds and Print proofs.

Optimization of specification to bring cost efficiencies.

Testing, validation and Issue of final Drawings and Specification including and KLDs for artwork.

Development of Test methods for testing all Packaging components.

Development of Supply guidelines for packaging material suppliers including Food safety.

Overall Benefits to the Business

Machine Capex reduction by 15%.

A cost reduction of 20% from the budget for packaging material.

One of its kind in market -a 2 Layer Thermoformed cup development to powerfully communicate the product cues.

A single point of contact for all packaging needs delivering end to end techno-commercial project management.

Innovation & Sustainability Led Growth Plan | Leading Personal Care Brand

Refill packaging

Innovation & Sustainability Led Growth Plan

Leading Personal Care Brand

BRIEF TO PACKFORA ​

Deliver packaging innovation to meet global sustainability commitment with inclusion of PCR, while delivering cost savings and consistent product performance

PACKAGING INNOVATION

01

Designed an innovative multilayer Rigid plastics Jar

02

Developed a consumer-friendly Refill system

03

Sustainability mix framework for packaging application

PACKAGING DEVELOPMENT

01

Develop supplier network for executing the innovation

02

Scouting technology solutions (Mold and Manufacturing process innovation)

03

Develop a cost reduction matrix

Overall Benefits to the Business

Delivering to the global sustainability mission of the organisation by inclusion of upto 50% PCR

Reduction of fossil based packaging material up to 50% with increased use of PCR

Up to 20% cost reduction to enhance brand margin

Ecommerce-ready pack

Innovation & Sustainability led growth plan | Leading paper manufacturer

Refill packaging

Innovation & Sustainability led growth plan

Leading paper manufacturer

BRIEF TO PACKFORA ​

A leading Indian paper manufacturer entrusted Packfora with the task of helping them build a strong pipeline of innovation for growth, centered around sustainability.

PACKAGING STRATEGY

01

Market sizing & analysis to identify multiple segments for innovation

02

Sustainability framework for current & future packaging applications

03

Facilitation of the innovation process for client stakeholders to generate idea portfolio

04

Market potential estimation and execution roadmap for shortlisted innovations

PACKAGING DEVELOPMENT

01

Identification of technical & performance specifications for current packaging

02

Development of alternate paper and enhanced paper-based innovations to replace current

03

Technical action standards for the identified new innovations

04

Identification of ecosystem partners to develop and pilot innovation

Overall Benefits to the Business

Structured understanding and analysis of market and segments

Opportunities spanning multiple segments - packaged food, food service, home & personal care

Accelerated development of new packaging offering ideas and their requirement specifications

Strong portfolio of sustainability led initiatives

Strong portfolio of sustainability led initiativesRoadmap for innovation led growth - over 10 key ideas with INR 300 Cr+ revenue potential

Accelerated packaging enhancements for re-launch (2D + 3D) | Personal Care Start Up

Refill packaging

Accelerated packaging enhancements for re-launch (2D + 3D)

Personal Care Start Up

BRIEF TO PACKFORA ​

Personal Care Start Up approached Packfora to ensure premium packaging solutions for re-launching in an accelerated time frame of just 8 weeks.

PACKAGING CHALLENGES

01

Existing packaging lacks in brand and shelf impact.

02

Key design challenge - to cue premiumness, with strong roots in technical formulation.

03

Packaging material selection not adequately appealing for the consumers.

04

Only 8 weeks left for re-launch timeline recovery.

PACKAGING DESIGN SOLUTION

01

Analysed category codes for packaging design and developed new designs.

02

Creative graphics and packaging to set the brand apart - both in terms of positioning and individuality.

03

Seamless and creative 2D (pack graphics) + 3D (pack structure) solutions appealing to consumer sensibilities.

PACKAGING STRUCTURE

Identified a range of stock vendors with different alternatives on material & finishes for proposed pack designs.

Quick prototyping solutions to provide mock-ups of alternative designs to validate final selection.

Vendor selection and commercial negotiation support.

Overall Benefits to the Business

Winning pack design with unique brand values and better shelf impact.

Access to a wide ecosystem of vendors to quickly select the best structure for re-launch pack.

Seamless support across design (2D) & structure (3D) for packaging to ensure fast turnkey solution.

Re-launch plan on track with new and significantly improved packaging in just 8 weeks.

Identifying value proposition for growth opportunities | Plastics Packaging Vendor

Refill packaging

Identifying value proposition for growth opportunities

Plastics Packaging Vendor

BRIEF TO PACKFORA ​

A leading rigid plastics vendor engaged Packfora to understand and improve their equity with customers and their customer pitch process.

BUSINESS CHALLENGES

01

Gap in terms of understanding the requirements of key customers.

02

Not able to articulate their own strengths in context of customer needs.

03

Improve customer engagement process and further Institutionalize it internally.

04

Business image not in sync with industry leadership status as a supplier.

OUR SOLUTIONS

01

Designed a framework to understand customer needs in terms of innovation, supply chain efficiencies, agility and sustainability.

02

Helped in recognizing and focussing on newer technologies which may be of interest to specific customers.

03

Identified key manufacturing and process strengths which can be highlighted for business opportunities.

04

Developed a process to prioritize and improve the articulation of own strength while pitching to meet customer needs.

05

Value added coaching provided to the internal team while preparing and reviewing a pitch deck.

Overall Benefits to the Business

Improved value proposition and engagement with customers in growth opportunities.

Enhanced capability of the internal team to identify customer needs and pitch more effectively.

Highlighted capability and market relevant solutions in areas like PCR usage, innovative labelling and embellishments, local source of advanced pumps, etc.

Fresh communication with some large but dormant customers, increasing the share of spend.

Initial customer presentations led to select new offerings move towards pilot engagement stages.

Sustainability & Simplified Packaging operations for business | Automobile Tyre Manufacturer

Refill packaging

Sustainability & Simplified Packaging operations for business

Automobile Tyre Manufacturer

BRIEF TO PACKFORA ​

A leading tyre manufacturer approached Packforato ensure the packaging structure used is in compliance with government guidelines of recyclability and to simplify packaging operations.

PACKAGING INNOVATION

01

Packaging materials need to be in sync with government guidelines on sustainability.

02

Complex packaging operations - multiple small volume SKUs, high inventories and variable printing frequency - need to be more streamlined.

PACKAGING DEVELOPMENT

01

Provided optimal specifications with sustainability norms, thus enabling 100% recyclability which helped meet government guidelines effectively.

02

Developed flexible packaging structure to reduce SKU complexity.

03

Introduced newer technologies in variable printing which helped in reducing print frequency.

04

Provided assistance to the client with end-to-end packaging supply chain planning.

05

Unlocked savings in terms of packaging materials cost.

Overall Benefits to the Business

Unique, 100% recyclable structure which sets them apart from competitors in the Automobile industry.

Massive improvement in packaging process - from manual to semi-automatic, increasing efficiency by 50%.

2X Faster time to market on packaging changes, thus gaining responsiveness for business.

Reduction in unskilled labour needs.

Savings potential for more than 1 crore INR p.a.

Identifying 360 & approach in design + deploy for innovative packaging

Refill packaging

Identifying 360 & approach in design

deploy for innovative packaging

BRIEF TO PACKFORA ​

A leading global foods company approached Packfora to develop end-to-end innovative solutions for their coffee brand launch.

PACKAGING EVOLUTION

01

Benchmarking Market best practices

02

Technology 2 stage moulds development Manufacturing develop decoration routes

03

Sourcing Technology selection supplier infrastructure Cost modelling and negotiations support

PACKAGING DEVELOPMENT

01

Competition benchmarking to make right business choice

02

Barrier extrapolation to cut down on storage stability time

03

Developed cost-effective local quality supply partners for agility

Design for ease of Filling, Headspace, Batch Coding and Transportation

Fail-fast design iterations before mould making to ensure first time right

Delivered a consumer centric design

Overall Benefits to the Business

Ergonomic and optimized consumer centric design delivered

First time right Jar and Closure delivery, fast launch

Modular design to have flexibility to launch quick & low Capex for new shapes and sizes

Significant rebates in Capex due to design standardization

Recyclable packaging footprint

Develop strategy to enable sustainable packaging transition

Refill packaging

Develop strategy to enable sustainable

packaging transition

BRIEF TO PACKFORA ​

The African Government Development Board & a Leading Development Agency approached Packfora to provide technical and industry expertise to enable sustainable packaging transition at country, region & industry level.

SCOPE OF ENGAGEMENT

01

Develop an outline of strategy to enable sustainable packaging transition at country, region & industry level.

02

Identify specific policy measures, investment opportunities and prospective investor partners to help drive shift to viable sustainable packaging solutions for local economy and region.

RESULTS DELIVERED

Identified current state of packaging material usage and policy implementation in the local economy.

Identified current state of packaging material usage and policy implementation in the local economy.

Outlined necessary policy framework including EPR, PCR and governance mechanisms for sustainable packaging transition in local economy.

Benchmarked current packaging to global standards required for export in specific industry segments. Identified relevant scale & technology solutions to enable more sustainable packaging structures and recycling in the local economy & region.

Identified potential investment partners in four key material and industry areas. Enabled introductions for development bodies to initiate investment promotion

360° packaging expertise for end to end seamless execution leading foods company

Refill packaging

360° packaging expertise for end to end seamless execution

leading foods company

BRIEF TO PACKFORA ​

A leading foods’ manufacturing company approached Packfora for its packaging expertise and to partner with them on their visionary journey to revitalise the brand and business

SCOPE OF ENGAGEMENT

01

Deliver packaging muscle for growth, innovation & sustainability.

02

Global sustainability expertise and ecosystem to enable packaging transformation.

OUR SOLUTIONS

01

Design to value support to fuel growth by bringing [email protected]

02

Stronger pipeline for long term innovations and savings.

03

Packaging sourcing supply chain optimization by make or source study.

04

Managed packaging processes for speed and scale of program execution.

OVERALL BENEFITS TO THE BUSINESS

First principle, science and technology-based approach to unlocking value.

Created a portfolio of proprietary packaging innovations.

100% plant based renewable polymers for non fossil based plastics packaging.

100% plant based renewable polymers for non fossil based plastics packaging.

Redesign of tin cans, exploiting the double reduced technology

Re-engineered boxes leveraging structural design, moisture coating, performance-based paper.

USD 10 mn savings delivered within the first 12 months, USD 50 mn capital unlock from asset optimization.