Packaging Redesign – Single Service Hot Sauce Packaging
Packaging Design Challenge
What an exciting project! A hot sauce manufacturer reached out to BoldtSmith Packaging looking for a re-design on their current single-serve packaging. BoldtSmith developed multiple single-serve packaging design concepts that enhance this iconic brand and increase the customer experience when using their product. These concepts would be presented to a cross-functional team including marketing from headquarters and manufacturing from the plant. Including both marketing and manufacturing is critical when vetting packaging solutions.
Requirements
- Consider user experience & marketing value
- Reduce individual packet & master carton cost
- Present multiple designs to be marketing & manufacturing teams
BoldtSmith Actions
We broke the plan to develop these packaging concepts into five steps:
- Competitive benchmark: What is the competition doing for single-serve packaging? What are other product categories doing for single-serve packaging? What is working and what is not working?
- Brainstorm session: Group collaboration with all BoldtSmith Packaging Engineer’s to brainstorm all potential packaging solutions.
- Create package renderings: Utilizing our in-house graphic designer and packaging engineers, we designed multiple packaging concepts ranging from the opening price point to a premium packaging experience.
- Acquire pricing: What happens when you present the packaging concepts to manufacturing? The first question is “How much do they cost”? To answer this, we contacted both packaging suppliers and machinery manufacturers for budgetary pricing.
- Present the options: Detail the advantages/disadvantages for each design along with a financial analysis comparing the piece price of each concept, master carton costs, pallet patterns and capital investment needed for packing machinery.
Real Manufacturable Designs
Multiple designs of varying sizes
Cost-effective designs
Various budgetary price points
BoldtSmith does not provide concepts that look great in a fancy PowerPoint but cannot be manufactured. We provide solutions vetted for manufacturability with pricing and key data points for the customer to make an informed decision on which they would like to pursue.
Industries Served

Military
BoldtSmith packaging engineers design, implement and audit military packaging following stringent testing standards with documented precision.
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MFG Assembly Lines
In a world of high-speed manufacturing and assembly lines, packaging must be designed to match the line's efficiency.
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Food & Beverage
Whether the customer is a brand on the store shelf or private labeling a product at a co-packer, we have experience in executing solutions at all levels within the food & beverage world.
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E-Commerce
Our Amazon A-pass certified consultants utilize modern technology in data recording devices, allowing us to create a testing protocol that is custom to our customers' specific supply chain.
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Industrial
Reducing product damage, freight and material costs are common goals we are tasked with when optimizing industrial packaging projects.
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Furniture
BoldtSmith Packaging works with assembled and knock-down furniture companies creating optimized packaging designs to drive down damage and packaging costs.
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Consumer Packaged Goods
Our CPG experts have experience working both on the retailer side of the business and the product manufacturer side.
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Get started - Optimize your packaging now!
Save on materials, freight, product damage and labor costs while promoting your brand with BoldtSmith package engineering.
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