The Concept:

Traditionally companies put their products (televisions, toys, radios, pcs, small and large appliances, etc...) into foam, then they enclose all the supporting pieces and manuals into an accessory tray, then the all that goes into a corrugated outer carton.  It typically looks something like this: 

The question becomes, what is really needed? The example above clearly demonstrates "the way it's typically done".  But if we set aside that historical fact and approach the question purely on the basis of need, there may be a better, more simple and straightforward option. At least in some cases, and yours might be one of them.

This is a pharmaceutical package, molded foam only - no outer corrugated or film. This pack is shipped nationwide in high volume, every single day.

Do you really need interior and exterior packaging? Another way to go about it is to make the interior pack do all the work.

L - Lower Costs

I - Increased Protection

T - Through

E - Engineered Solutions

Because virtually any shape is possible when using molded foam and with the advances in film technology, projects are actually in production using no corrugated outer carton (see the picture below and think steaks)!  We have other similar projects under development.  Could you make this switch?

 

 Products in production right now:

 

Want some information about part design? part design