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Packaging and Merchandising Design - Exercise 2

06/10/25 -  13/10/2025 (Week 3 - Week 4)
Anggia Tsani Rachmadiyanti, (0368487)
Packaging & Merchandising Design / MER60104 / Bachelor in Design (Hons) in Creative Media / Taylor's University
Exercise 2 - Custom Boxes for Non-Boxed Items Prototype



 Content List: 

 Module Brief: 


 Exercise 2 Instructions: 


Designing Custom Boxes for Non-Boxed Items: 

The objective of this exercise is to develop your skills in creating custom packaging solutions for items that do not come in traditional box packaging. By the end of this assignment, you should be able to demonstrate your ability to design functional, creative, and visually appealing boxes that enhance the packaging and presentation of non-boxed items. 

Item Selection: Choose a non-boxed item from your daily surroundings. The size of the item is between 15cm to 20cm. This items should not come in traditional box packaging but should be relatively small in size. 

Justification: Provide a brief justification for your selection of these items, explaining why custom box packaging would enhance their presentation and functionality.
Box Structure: Create detailed diagrams or sketches of the box structure for each item, including dimensions, flap designs, and closure mechanisms. Ensure that the proposed box is functional and secure. 

Prototype: Create physical prototypes of the custom boxes for both selected items. You can use cardboard or other suitable materials to bring your designs to life.

 Lecture Notes: 

Week 3:
  • Packaging impacts the way we live in this global society. 
  • Packaging has to meet the demands of changing consumption, locations and occasions. 
  • Packaging is the container /wrapping that holds a product and protects it.
  • Packaging design - process of making the package look attractive and appealing to the consumer, while considering factors such as the target audience, brand identity, and practical considerations like ease of use and sustainability. 
  • Target audience important to study:
    • Age group, urban/rural, gender
  • Effective packagings make their product stand out and connect with consumers on an emotional level.
    • Colour
    • Typeface design
    • Shapes/graphics
  • Purpose & Function of Packaging:
    1. Protection
    2. Identification
    3. Transportation
    4. Differentiation
    5. Communication
    6. Marketing
  • Physical Protection - One of the primary functions of packaging is to protect the product inside. Packaging must be designed to keep the product safe from damage during transport, storage, and handling. 
  • Identification - Packaging is often used to help customers identify a product quickly and easily. Effective packaging design includes the product name, logo, and other important details that allow customers to easily recognize the product on shelves or online.
  • Transportation - To easily and safely move the product from the manufacturer to the consumer. 
  • Differentiation - Packaging help a product stand out from its competitors. Effective packaging design should be distinctive and memorable, with unique color schemes, typography, and imagery. (for eg: Same brand, different flavours.)
  • Communication - can be used to communicate important information about the product, such as its features, benefits, and usage instructions. Effective packaging design should include clear and concise messaging of what the product is about.
  • Marketing - Packaging also used as a powerful marketing tool, helping to create a positive impression of the brand and product. Effective packaging design should align with the brand's overall marketing strategy and messaging, creating a cohesive brand identity, resonates with customers.
  • Information on packaging - 
    • Product name: The name of the product must be clearly displayed on the packaging so that customers can easily identify what they are purchasing. 
    • Net quantity: amount or weight of the product contained in the packaging must be indicated, usually in both metric and imperial units.
    • Ingredients: If the product contains any allergens or other ingredients that may cause harm to consumers, these must be listed.
    • Nutritional information: calorie count, fat content, and sugar content must be included.
    • Country of origin: The country where the product was made must be stated on the packaging.
    • Manufacturer information: The name and contact information of the manufacturer or distributor of the product must be included.
    • Warning labels: Certain products may require warning labels to inform customers about potential hazards or risks.
History:
  • Ancient Times:
    • Natural materials like: Leaves, bark, coconut shells, bamboo, and animal skins to wrap or carry food and items. 
    • Ancient Egyptians and Chinese - clay pots to store oils, grains, and spices.
  • Early Civilizations (Mesopotamia, Egypt, Rome) 
      • Glass bottles and clay amphorae introduced for storing olive oil, wine, and medicine.
      • Romans started labelling their containers using clay seals.
    • Industrial Revolution (1700s–1800s) 
      • Major shift in packaging due to mass production and factories. 
      • Peter Durand invented the tin can for preserving food. 
      • Paper packaging and cardboard boxes began being widely used in shipping.
    • 20th Century (1900s–2000s) 
      • Packaging became more commercial and visual, thanks to supermarkets and advertising.
      • Plastic packaging became popular – cheap, lightweight, and versatile. 
      • Coca-Cola and Kellogg’s started using signature colors, logos, and typography to stand out.
    • 21st Century – Era of Sustainability & Digital
      • The focus shifted towards eco-friendly packaging – biodegradable, recyclable, less plastic.
      • Many brands now use paper, glass, and reusable materials.
      • Rise of smart packaging – like QR codes and NFC tags for interactive experiences.
    • The design of packaging must consider various factors:
      1. Target audience
      2. product positioning
      3. brand identity
      4. marketing strategy. 
    • Elements, such as: shape, color, typography, imagery, and material choices. These elements work together to create a cohesive and visually appealing package.
    "As a Designer, it is important to monitor and consider the processes of design, evaluation, and production of packages to bring out most of the concept and intended message for the product."

    Week 4:
    • Common Types of Boxes in Packaging:
      • Folding Cartons
      • Rigid Boxes
      • Set-up Boxes
      • Cardboard Boxes
      • Corrugated Boxes
      • Paperboard Boxes
    • Folding Cartons - eg: Cereal boxes
    • Rigid boxes - 
      • (set-up boxes) are sturdier and do not fold or collapse as folding cartons do
      • They are often, not always used for higher end products where perceived value is important
      • They are also used when the product within is heavy and in need of extra support.
    • Corrugated cardboard -
      • Also called corrugated board, corrugated fibreboard or combined board
      • Commonly refer as brown cardboard boxes
      • Typically has three layers
      • also used in store display racks
      • A wavy or fluted layer sandwiched between two outer flat layers
      • The fluted layer is where the strength of this paper product lies
      • Often referred as “shipper boxes” or “master packs”. Mostly used to ship a company’s retail-ready products to stores all over the country/world
    Common Elements in Folded Cartons:
    • 2 types of tuck top boxes:
      • Reverse Tuck End (RTE) - Health and beauty, Cosmetics, Pharmaceutical, Electronics
      • Straight Tuck End (STE) - Health & Beauty / cosmetics
      • Tuck Top Snap - Lock Bottom - good for heavier objects (toys, food, etc.)




    (Fig. 1.0) - Week 4,  types of box lock and tucks

     Exercise 2 Progress: 

     
    (Fig. 1.1) - Week 3,  Measurement of my perfume bottle and cream

    (Fig. 1.2) - Week 3,  Measurement of my final chosen products

    I plan to make a set gift box of 3 mini cylinder perfumes. And my second idea would be a box for 2 mini perfume + 1 body lotion set. All are from the same brand.

    Justification: Currently, the Bath & Body Works mini perfumes and lotion is sold without any form of outer packaging. While each item is visually appealing on its own, introducing a custom box packaging with a handle offers several functional, marketing, and aesthetic advantages. It's made of hard acrylic plastic so we need to protect it as it can crack easily when you drop it.

    1. Protection and Organization - A box ensures better protection during handling and transportation. The current unboxed items are prone to scratches, leaks, or damage when displayed or carried. A structured box with tray and secure compartments helps keep the bottles upright and prevents movement or breakage. It also allows the set to be neatly organized and presented as a cohesive unit rather than loose individual items.

    2. Enhanced Gifting Appeal - Bath & Body Works products are often purchased as gifts. A thoughtfully designed box with a handle instantly elevates the perceived value, making the set look more premium and ready for gifting. The handle adds convenience for customers, allowing them to carry it easily without needing an additional shopping bag. This design supports seasonal sales such as holidays, birthdays, and special occasions.

    3. Reusability - The box can be reused for customers who may reuse the box for storage or travel, extending the brand’s presence in their daily lives.

    Inspirations & Sketches:

    (Fig. 1.3) - Week 3,  Sketches/drafts ideas on boxes

    (Fig. 1.4) - Week 3,  drafts ideas on boxes

    First try (Week 3):

    I first tried to make mockups & trying to make the insert for 3 of the items so that it will stay in place when put into the packaging box later on..


    (Fig. 2) - Week 3,  Making the tray mockup for the perfume and lotion box

    I tried making one mockup which is shaped like a bag. However, I didn't like this one as it is quite hard to open and I think it would look better if we can see the whole 3 objects using a clear plastic sheet instead of making 3 rectangle holes:

    (Fig. 2.1) - Week 3, trial (failed) using kraft paper

    (Fig. 2.2) - Week 3, trial (failed) using kraft paper

    (Week 4) - Revise & Final mockup :

    I made a lot of mockups as I had several issues with the measurements especially when it comes to considering the thickness of the cardboard. I decided to use a 1mm thick cardboard for the final packaging. I bought the cardboards in Weststar melawati store and Advanco, as they have so many choices to pick from, as well as bought a transparent sheet for the window later on.

    I did my final mockup with the handle string attached to test it out and which Mr. Shamsul said looks good. I made the window frame abit more fancy with the 3 curves since it is lotion and perfume products to make it look more feminine. There were many trial and errors as well just to finalize the correct measurements.


    (Fig. 2.3) - Week 4, final mockup of packaging

    (Fig. 2.4) - Week 4, final mockup making process

    (Fig. 2.5) - Week 4, final mockup making process

    (Fig. 2.6) - Week 4, final mockup making process/open view

    Once the test mockup fits perfectly, I started doing my die cut / dieline on Illustrator to prepare for laser cut. The red outlines are the lines needed to be laser cut:

    (Fig. 3) - Week 5, Dieline illustrator process

    (Fig. 3.1) - Week 5, Dieline JPEG

    (Fig. 3.2) - Week 5, Measurements

    (Fig. 3.3) - Week 5, Final Dieline PDF

    Notes on making the die line in Illustrator:
    • Always do in CMYK mode and must be in "mm" not "cm".
    • All lines must be 0.5pt
    • Can use pen or rectangle tool.
    • Export as "dxf" file
    (Fig. 4) - Week 5, save AI File format as .dxf for laser cut

    Laser Cut:
    • After finalising the die line, I went to Taylor's Makerspace and used the laser cut machine to make my trimmed final die cut.
    • After the laser cut, I folded it myself as I found that it is safer to do the foldings manually
    (Fig. 4.1) - Week 5, Laser cut

    FINAL OUTCOME:


    (Fig. 5.1) - Week 6, Final Outcome, Front View

    (Fig. 5.2) - Week 6, Final Outcome, Back & Top View

    (Fig. 5.3) - Week 6, Final Outcome, Front Empty View

    (Fig. 5.4) - Week 6, Final Outcome, Opened View

    (Fig. 5.5) - Week 6, Final Outcome, Locking System

    Feedbacks:

    Week 3
    General Feedback - Mr Shamsul gave us the lecture on packaging design and what should be on a packaging design. He also started briefing us on our 2nd exercise to pick a non-boxed item that is at least 15 cm and start making a sketch on the box packaging for week 4 class.
    Specific Feedback - Mr. Shamsul said that if we can't find a 15 cm object, we can use a smaller object but make a set or bundle of it.

    Week 4
    General Feedback - We discussed as a class that for project 2 it is going to be a group project.
    Specific Feedback - Mr Shamsul said my final idea sketch is good. He just told me to change the alignment of the tray for the 3 objects so it is aligned at the bottom, and he also suggested me to make the plastic clear frame to have rounded edge to give a more feminine look. He said I can add and seal the string for the handle and told me to use a thick cardboard for the final packaging. Thinner than corrugated. 

    Week 5
    General Feedback - Mr Shamsul did a short online meeting tutorial during holiday on how to create the dieline on illustrator.
    Specific Feedback - Sir said mine look sgood already and I should book for laser cut. He also said that it's better to fold the lines myself. It's risky if we make the machine do the foldings.

    Reflections:

    Experience:
    • Throughout this project, I explored the process of designing custom packaging for a non-boxed item: a mini set consisting of two perfumes and one lotion. It was a challenging yet rewarding experience because I had to translate a 2D dieline into a 3D physical structure that fit the products precisely. The most difficult part was ensuring the dimensions were accurate and that the flaps folded neatly without leaving gaps or misalignments. I went through multiple trial and error stages, adjusting the measurements and construction until the final prototype fit the items securely. Despite the difficulties, seeing the finished box come together gave me a sense of accomplishment and confidence in my ability to create practical and attractive packaging solutions.
    Observations:
    • During the process, I observed how small design decisions, such as where to place folds, how thick the cardboard should be, or what type of closure to use, greatly affected the final outcome. I realized that even a few millimeters of difference in measurement can change how well the items fit inside the box. Material choice also played a major role, like thinner cardboard was easier to cut and fold but lacked sturdiness, while thicker material provided better protection but required more precision in scoring and folding. This made me more aware of how technical considerations, like material thickness and structural balance, must work together with aesthetics to achieve a professional and functional packaging design.
    Findings:
    • From this exercise, I learned that successful packaging design requires both creative and technical thinking. It’s not just about visual appeal but also about structural logic and user experience. Visualizing the dieline helped me understand how flat designs transform into tangible 3D forms, and how every fold and tab contributes to the overall stability of the box. I also found that testing and prototyping are essential steps to refine design accuracy. In future projects, I will pay closer attention to material behavior, cutting precision, and ergonomic factors, as these are key to ensuring the packaging not only looks appealing but also functions effectively.


    SEM:

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