Case Studies
Packaging Optimization & Design
Optimized packaging designs from BoldtSmith packaging engineers have saved our clients millions of dollars in material, labor and freight costs. Better packaging solutions can result in more product shipped per pallet and better consumer response. Here are some of our clients’ success stories.
Insight Cart Packaging Design
Create a new, cost-effective design that would provide the most efficient packaging solution for Insight medical carts
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Cold Chain Packaging Solution
Developing a cold chain packaging solution for chocolate shipping small parcel
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Packaging Advantage - Speed
Optimized ecommerce packaging design developed, tested & sent for pricing in just 3 business days.
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Packaging Advantage – Expertise
Analyzing every step in the supply chain with custom testing resulted in a 25% reduction in freight and 46% redution in packaging material costs.
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Corrugated Material & Freight Cost Reduction
$6,000,000+ annual cost savings realized from BoldtSmith’s optimized packaging solutions, samples, and specifications.
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Corrugated Packaging Cost Reduction
$2,058,306 annual reduction realized in packaging material and freight savings, 32% reduction in master carton cost and 16% more product per pallet.
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Johnsonville’s Sausage Strips
Over two hundred retail package design options were created, reviewed, researched, and evaluated for the best consumer response.
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Photo Film Packaging – Cost Savings
Packaging optimization results in $1.4 million dollar cost savings
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Amazon Frustration-Free Packaging
33% average reduction in package size, 36% average increase in packages per pallet and 1,944 more packages per ocean container on average.
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Damage Reduction for Furniture
Packaging material costs reduced by 10% and damage reduced from 6% to 0.5%.
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Too Many Boxes?
Have too many box designs? BoltSmith reduced total cartons used from over 100 down to 20, saving over $300,000 annually.
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Hot Sauce Manufacturer
hot sauce manufacturer reached out to BoldtSmith Packaging looking for a re-design on their current single-serve packaging.
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Modular Crate Design – Building Products
Modular crate design for a railing assembly manufacturer
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Eco-Friendly Packaging
Reduce, Reuse, Recycle. The three pillars of sustainable packaging, each of which has potential for packaging cost reduction.
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Confast Drop in Anchor Packaging Design
BoldtSmith Packaging was then able to create a financial analysis comparing all 3 packaging options.
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Retail Packaging Renderings – Fishing Reels
Created 3D renderings for a large fishing reel manufacturer
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3D Renderings vs Photography, Which is Better?
3D Renderings vs Photography, Which is Better?
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Shipping Orientation
Changing ONLY the packaging orientation fits 20% more product shipped per container, saving $460,000 in freight costs annually.
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POP Modular Display – Desert Decorating Products
1,000+ product SKUS consolidated into three POP displays
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Shower Door Base – Cost Reduction
A company that manufacturers shower doors and bases reached out to BoldtSmith Packaging to reduce costs associated with the below variables.
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Appliances – LTL Damage Reduction
Decreased damage for high end appliances shipping LTL.
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Work Gloves – Costco Packaging Design
Costco product launch that required new structural packaging designs.
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Returnable Packaging Design
Returnable packaging solution develop, sampled, tested and implemented.
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SIOC Ecommerce Packaging Optimization
BoldtSmith Packaging redesigned Melissa & Doug's packaging, increasing efficiency and sustainability by 21-187% per ocean container.
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Clients We Have Served
Customer Reviews
It was excellent working with Dave Branson throughout the project process. It was a very informative professional analysis of our problem. We had regular calls and the project deliverables were completed as promised.
Ken Boswell
Sr. Department Manager, Mechanical Engineering
Sharp Manufacturing Company of America
BoldtSmith did a good job executing on the assessment phase of the project. Very responsive and communicative. Attentive to needs, changes. Reliable. Dustin did a good job leading the work
Federico Eramo
VP Strategic Projects & Business Transformation
BJ's Wholesale
BoldtSmith has been a great partner throughout the design process. They are extremely responsive to their customers’ needs. We had a product form factor change that resulted in a need to change our packaging design. Within one day they had a prototype to us, and within less than four days they were able to test the new design to ISTA standards. After less than a week we had a fully validated updated design with drawings and artwork. This was critical to keep our project on schedule.
Katie Milbeck
Senior Manager, Innovation Incubator
Brady Corporation
