Retail-Ready Snack Bar Packaging
I developed the final retail-ready carton structure for a 12-pack snack bar format, engineered for automated side loading and conversion into a consumer-facing display.
I worked with the co-packer’s automation team to optimize the carton for machine handling, developing and testing the structure through physical prototypes before releasing the final design for trial production and machine testing.
Client
Confidential
Type
Retail-Ready Packaging
Year
2025
Process
Engineering for Automated Packing
I optimized dust-flap geometry and product clearances for automated side loading and machine tucking. Full hairpin slots were incorporated to reduce flap interference, and I coordinated with the co-packer’s automation team to prepare the final structure for machine trials.
Developing a Clean Retail Opening
I tested multiple perforation configurations to balance structural integrity with clean tear performance. The opening needed to remain secure through handling while releasing predictably and leaving a clean edge for retail presentation and consumer access.
Creating the Display Conversion
The tear-out panel folds along an integrated crease and engages with retaining slits to form a secured display header. This converts the closed 12-pack into an open retail display with individual snack bars accessible for purchase.
Outcome
The final structure progressed through physical prototyping and co-packer collaboration to trial-carton production for machine testing. The design combined automated packing requirements with a clean, intuitive conversion from closed carton to retail display.
