BoldtSmith Packaging - Returnable Packaging
Packaging Design Challenge
A customer reached out to BoldtSmith Packaging to develop a returnable packaging solution that will be used to ship automobile components from the OEM to the assembly plant.
Requirements
- Understand the client's entire supply chain
- Financial analysis for returnable vs expendable packaging
BoldtSmith Actions
By leveraging our internal packaging design team and working with an identified packaging supplier, we worked to brainstorm, design and implement a returnable packaging solution.
- Brainstorm potential packaging solutions
- Create multiple returnable packaging concepts
- Manage the creation of packaging specifications
- Manage the creation of packaging samples
- Send specifications for pricing
- Create financial analysis including packaging, labor and freight costs to calculate the ROI for returnable vs expendable packaging
- Present the design, pricing and testing results
Return on investment
The analysis in this project determined that a returnable packaging solution made sense for the customers specific supply chain
3x Return on invesment
At BoldtSmith Packaging, our number one goal is to exceed customer expectations. Speed is one of the many ways we do this.
Packaging Design Process
By working with our internal packaging design team and leveraging an existing packaging supplier to the customer, we were able to successfully brainstorm multiple packaging concepts. From there, we obtained budgetary pricing to determine what the ROI time frame would be to transition from expendable packaging to returnable packaging.
Based on the data gathered, it made financial sense that a returnable packaging solution could be a good fit. From there, our team developed packaging specifications, samples and completed testing. Testing included line trials on the semi-automated lines to determine if adjusted needed to be made to fit the current process. After a successful line trial, transit testing was completed in an ISTA approved lab that replicated their specific supply chain. Ship testing was also completed between the OEM and assembly plant to identify any potential issues.
Returnable and Expendable Package Designers
Debating on whether your product should be shipped in a returnable or expendable packaging solution? Reach out to BoldtSmith Packaging and we will complete the analysis to give you a data driven recommendation.
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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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Save on materials, freight, product damage and labor costs while promoting your brand with BoldtSmith package engineering.
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