Master Lock
Secondary Packaging Solutions
Project Scope:
Standardize lock box packaging structures across the platform to achieve a more consistent presentation. These structures should allow for the end consumer to interact with them prior to purchasing.
These need to be able to stand alone or hang from peg hooks. The unboxing experience should be simplified from the existing structures. Ideally there will be no plastic used for these structures. If paperboard material is used it must be FSC certified or recycled.
Company: Jansy Packaging
Client: Master Lock
Role: Packaging design and development, CAD modeling, Custom die lines, Prototyping and testing, 3D rendering, Factory communication
Approach
Analyzing Current Challenges
The lack of structural commonality creates comparison difficulty across the platform on the store shelves. The usage of plastic materials do not align with customer/TMLC sustainability goals. Plastic components carry higher cost vs paper-based materials. High costs are driven by returns from end users as the product can’t be resold when the packaging has been opened. Our team visited stores to interact with these structures up close to familiarize ourselves with them.
Development
Defining New Packaging Objectives
During this stage I focused on using paperboard concepts to meet the objectives set out by the Master Lock team. I considered customer interaction, product visibility, adaptability for varying SKU's and the overall unboxing experience. Our team narrowed down a few ideas that I validated through physical mock-ups using a CAD cutting table and 400gsm cardstock.
Refinement
Feedback from the Team
After the first round of concepts were presented, the Masterlock team gravitated towards the Hang Card design due to it's minimal material usage and visibility of the product. Their main concern was limited print space so I went back to the cutting table and explored alternative ways to expand upon this idea.
Final Designs
Photorealistic Renderings
The final designs for all four SKU's were presented to the Masterlock team for approval. I worked closely with our graphic design team to ensure all necessary legal information was included on the printable space as well as translations for Europe and Japan since these were going to be sold globally.
Touch Points
Interactive Design
Each secondary structure was designed in a way that encouraged users to interact with the product. They can be hung on store racks or stand in rows of four on shelves. Each structure is also 100% recyclable and easily removable so consumers can take these apart without ruining the packaging.