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Water bottler loses a panel, gains an edge

A new secondary packaging design that uses a three-sided tray for bottled-water multipacks provides cost and sustainability benefits for Premium Waters.

Pw 2597 0 5 Ltr 24 Pk Ltwt 3 Sided Tray 2

In 2008, the company engaged Georgia-Pacific’s Packaging Systems Optimization™ (PSO) program to evaluate its secondary packaging. Through the PSO program, Georgia-Pacific reviews a customer’s packaging supply chain to identify opportunities to reduce waste, enhance efficiency, and strengthen sustainability. The solution Georgia-Pacific found for Premium Waters was a new way of bundling bottled water that enhances sustainability and provides greater profitability.

Data-driven process for redesign
Established 130 years ago, Premium Waters today distributes a complete branded line of waters, as well as various private-label brands for retailers, grocers, and convenience stores.

Several years ago, Premium Waters enlisted Georgia-Pacific’s PSO team to evaluate its secondary packaging—corrugated trays holding 24-packs of 0.5-L bottles, wrapped in 2.5-mil low-density polyethylene shrink film—for sustainability opportunities. In the five-step PSO process, a team of packaging engineers analyzes a company’s entire packaging supply chain, focusing on areas such as package design, material optimization, shelf impact, alternative packaging, and SKU consolidation, as well as productivity improvements, warehousing, material handling, and transportation.

For the Premium Waters project, the PSO team worked closely with Premium Waters and its proprietary film supplier to redesign the original four-sided multipack tray into a three-sided package. Data was gathered on current cost versus proposed cost, including corrugated material, shrink film, glue consumption, and productivity impact. A Total Cost Analysis (TCA) was then generated to determine the estimated cost savings based on all the data points to determine both the financial and sustainability impact.

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