How Engineered Industrial Packaging Can Reduce Damage Rates and Total Cost of Ownership (TCO)

The demands of modern supply chains are higher than ever: products need to arrive quickly, securely, and at a low cost. In this efficiency-driven era, engineered industrial packaging has become essential for operational success. It protects products, reduces costly damage, and lowers overall spending through improved Total Cost of Ownership (TCO).

Smurfit Westrock Packaging Solutions leads the way in providing innovative, sustainable, and reliable packaging solutions that help businesses thrive.

What Is Engineered Industrial Packaging, and How Does It Affect Total Cost of Ownership (TCO)?

Engineered industrial packaging refers to solutions specifically designed to meet the needs of a particular product, application, or market segment. Unlike off-the-shelf options, engineered packaging focuses on fit, protection, and performance across the entire supply chain. It combines:

• Material selection based on product vulnerability and transit conditions
  
• Structural design for optimal support, stacking, and space utilization
  
• Customization to ensure packaging aligns with production, storage, and shipping needs
  
  

Total Cost of Ownership (TCO) in packaging represents not only the upfront cost of materials, but also every cost incurred throughout its lifecycle. Key overlooked expenses include:

• Product damage and returns from inadequate protection,
  
• Extra storage or handling costs due to inefficient package design,
  
• Waste management and disposal fees,
  
• Environmental impacts that may soon carry direct regulatory costs.
  

By addressing these hidden pain points, engineered industrial packaging delivers substantial long-term value.

How Engineered Packaging Reduces Damage and Optimizes Supply Chain Efficiency

Too often, generic packaging fails to match the real-world shipping challenges. Common failures include insufficient cushioning, weak structural support, and materials unsuited for moisture or vibration. Custom-engineered solutions offer much more than simple containment:

• Enhanced protection: Reinforced inserts, advanced cushioning, and right-sized compartments help minimize shock and vibration during transit.
• Streamlined packing: Designed with the packer in mind, custom solutions speed up workflows and reduce packing errors.
• Improved load optimization: Better space utilization means more products per pallet or truckload, resulting in lower freight costs.
• Better ergonomics: Custom packaging often improves safety and handling ease, reducing injury risks and downtime.

This was the case for a leading industrial client that partnered with Smurfit Westrock Packaging Solutions to optimize its existing packaging. By re-engineering the design, they reduced material usage by 60% while maintaining product integrity, resulting in significant cost savings, reduced waste, and a faster production line. Read the full case study here: Material Reduction Win.

Lowering Hidden Costs and Driving Sustainability

Sustainability remains a growing expectation across various industries. According to McKinsey, 77% of U.S. consumers consider recyclability the most critical packaging attribute, and nearly 70% place the responsibility for sustainable packaging on brand owners and packaging producers, not the end consumer.

That’s why engineered packaging plays such a critical role. It enables companies to meet these evolving expectations while simultaneously driving down operational costs. Every layer of optimized packaging helps businesses meet sustainability goals while saving money:

• Lower material use equals lower material costs: right-sized and recyclable materials reduce ongoing expenses and simplify procurement.
  
  
• Less waste equals lower disposal fees: efficient packaging design means less excess and lower end-of-life handling costs.
  
  
• Fewer damages equals fewer claims and returns: this directly strengthens your TCO and improves customer satisfaction.
  
  
• Better sustainability equals a better brand reputation: eco-conscious packaging not only reduces your carbon footprint but also aligns with customer and regulatory expectations.
  

It's Time to Rethink Your Packaging ROI

Engineered industrial packaging is a strategic investment that pays dividends by reducing damage rates and lowering Total Cost of Ownership. Through innovation, customization, and a focus on full lifecycle value, businesses can boost supply chain efficiency and sustainability.

Working with a dedicated packaging engineering partner provides clear advantages that go far beyond simply ordering boxes. Smurfit Westrock Packaging Solutions sets itself apart through:

• In-house engineering and design that leverages the latest materials and manufacturing methods.
• A deep commitment to sustainability through ongoing research and industry-leading options in recyclable, biodegradable, and compostable packaging.
• Cross-industry expertise, allowing them to apply best practices from a wide range of sectors to your unique needs.

With a comprehensive approach, Smurfit Westrock Packaging Solutions guides clients from initial needs assessment and design, through prototyping, testing, and ongoing logistics support. Every solution is measured against both protection and cost benchmarks to ensure genuine value at every step.

Explore how engineered packaging can reduce damage and improve your TCO. Contact our experts today and take the first step toward smarter, safer, and more sustainable packaging.