Bonnie Plants Carrier
I developed a paperboard four-pack carrier for Bonnie Plants, designed to securely contain and carry live plants for retail at Costco. With only empty pots provided, I established the structural requirements around product fit, plant variability, consumer handling and efficient pack-out.
I led the structural design from concept and material selection through prototyping, manufacturing development and commercialization for Costco.
Client
Client
Type
Structural Packaging
Year
2026
Process
Designing around an unpredictable product
With only empty pots to design around, I developed the carrier to accommodate variations in plant height, weight and foliage while keeping each pot secure. I refined the individual cell sizing, containment height and handle clearance to limit shifting and tipping while maintaining easy access for carrying.
Balancing production with easy pack-out
I designed a glued auto-bottom for quick hand erection and worked with manufacturing to refine the nicking along the cell-forming cuts. The final design balanced reliable converting with clean, efficient erection during packing.
Adapting the carrier for in-pack watering
After commercialization, Bonnie clarified that plants were watered while still in the carrier, introducing direct water exposure beyond the original humid-environment requirements. I evaluated material and coating options and recommended targeted interior water resistance with structural drainage to address the exposure while controlling cost.
Outcome
The carrier was produced as designed and commercialized for Bonnie Plants at Costco, bringing the four-pack from an open structural brief through production and into retail.
