Structural Packaging Design and Sustainability
This course introduces the full process of structural packaging design, from briefing to concept development, with a focus on materials like paperboard, glass, metal, and plastics. Participants learn to balance functional and aesthetic requirements with practical constraints such as strength, barrier properties, and production feasibility, while integrating sustainability and regulatory compliance (e.g. PPWR).
Topics such as packaging functionality, cost estimation, intellectual property, and production equipment are also covered, with design decisions supported by scientific research and industry best practices.
By the end of the course, participants will be equipped to confidently manage packaging projects with a strong awareness of technical and environmental factors.
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This course is designed for professionals and recent graduates involved in packaging, product development, and sustainability, including:
- Packaging designers and engineers
- Industrial and product designers
- Brand managers and marketing professionals
- Sustainability and CSR managers
- R&D and innovation teams
- Packaging technologists
- Procurement and materials specialists
- Professionals working in FMCG, cosmetics, pharmaceuticals, and other packaging-intensive industries
- Anyone involved in packaging development who wants to gain deeper insight into structural design and sustainable material use
A background in product or packaging development is an advantage, though not strictly required. A basic level of general technical knowledge is recommended to fully benefit from the course. Participants will receive an introduction to a wide range of packaging materials, covering how they are produced, their applications, and also their limitations and unsuitable uses.
Instructor
Prof. dr. ir. Roland ten Klooster Roland ten Klooster is professor Packaging Design and Management and Promotor of the NVC Chair Packaging Design and Management at the faculty of Engineering Technology at the University of Twente (The Netherlands). Special research interests include the role of packaging in sustainability, how to design convenient packaging, the influence of packaging design on consumer behaviour, sealing of plastic films, new cellulose-based materials, and the processing of packaging on fast running packaging lines. Professor ten Klooster is also a member of the Committee of Independent Experts for the Netherlands Institute for Sustainable Packaging and works as designer/consultant at Plato product consultants to help clients with packaging related problems.Programme
DAY 1. From Function to Form: Foundations of Packaging Design
An introduction to packaging functions, design processes, and consumer influence.
The course begins with an introduction to the fundamental functions of packaging and how they influence structural design. Participants will explore problem-oriented thinking and learn the steps involved in structuring a design process. Key elements such as briefing, analysis, and defining requirements will be discussed, along with how to translate them into initial sketches. The day also covers stage-gate models, the stated purpose of packaging, and how functional and aesthetic choices – especially visual appearance – can influence consumer behaviour.
DAY 2. Paper, Board, and Print: Structure Meets Strategy
Exploring material-specific design, printing, and structured innovation methods.
The second day focuses on printing and the vulnerabilities of packaged products. Participants will dive into the design of paper and board packaging, including practical insights, case studies, and material-specific tips and tricks. In addition, several structured design methodologies will be introduced – TRIZ, QFD, Ishikawa, and FMEA – to support systematic innovation and risk management. The day concludes with further case studies in paper and board packaging.
DAY 3. Creativity and Materials: Designing with Innovation in Mind
Creative methodologies and practical insights into plastic and glass packaging.
Creativity takes center stage on day three, as participants explore design methodologies that foster innovative thinking. The course then shifts focus to plastic packaging – both rigid and flexible – providing practical design insights, common challenges, and real-world case studies. The day concludes with an exploration of packaging design in glass, highlighting its specific design considerations, possibilities, and constraints.
DAY 4. Metal, Wood, and Smart Packaging: Adding Value Through Design
Advanced materials, labeling techniques, and technical design tools.
This day begins with the structural and aesthetic aspects of designing in metal, followed by a look at wood-based packaging and emerging smart packaging technologies. Labeling and sleeving techniques will be addressed, including how they impact both function and appearance. The afternoon covers advanced technical topics such as finite element method (FEM) simulations, engineering plastics, and cost price estimation to help inform strategic design decisions.
DAY 5. Machinery, Law, and Sustainability: Packaging in Context
How equipment, legal frameworks, and circularity shape design decisions.
Day five offers a broad overview of packaging equipment and how machinery influences design choices. Legal aspects are also covered through a session on intellectual property. A significant portion of the day will focus on sustainability in practice, introducing tools and frameworks such as RecyClass, WRAP, CEFLEX, and KIDV to support circular packaging design. The day wraps up with a session on packaging for durable goods, with special attention to long-term performance and reuse potential.
DAY 6. Details That Matter: Components and Future-Proof Packaging
Focus on performance, recyclability, and real-world application.
The final day explores specific components that can greatly influence packaging performance and recyclability, including top seals, coatings, caps, closures, and adhesives. These will be discussed in terms of both technical function and sustainability impact. The course concludes with a wrap-up session that places the entire programme in perspective, encouraging participants to apply their learning through the discussion of practical, real-world cases.