One Flexible Packaging Design That Fits Three Products

How WynnPack cut SKUs, storage costs, and packing time for a three-oven product line — using a single universal honeycomb design

The Challenge

A manufacturer needed to ship three industrial ovens. Each unit was a different size. They wanted one packaging solution, not three separate designs.

The three units varied significantly in all dimensions:

Finding one design that could safely protect all three units was the key engineering challenge.

What the Customer Needed

The customer set six clear goals for the packaging:

• Use environmentally friendly materials

• Protect products during shipping and handling

• Keep costs low

• Make packing and unpacking fast and easy

• Minimize the number of SKUs

• Reduce storage space for packaging materials

The real challenge: one packaging family that could serve three very different product sizes — without waste, extra parts, or complexity.

The WynnPack Solution: Cookie-Cut Honeycomb

WynnPack designed a simple three-part system built around cookie-cut honeycomb pads and corner posts.

Here is how it works:

• The pads are cut to fit the largest unit — the 5 cu ft oven — perfectly.

• Need to pack the 3 cu ft unit? Snap off the first perforated section. The pad now fits the medium oven.

• Packing the smallest 1 cu ft unit? Remove one more perforated section. Done.

The corners work the same way. One set of corner posts fits all three ovens. Each unit only uses what it needs.

For the outer carton, the small unit ships in a standard RSC box. The two larger units use a corrugated tray with an HSC cover — making them easy to load and easy to open at the destination.

The Final Design: Just 3 Parts

The complete solution uses only three components:

Component Details

Top & Bottom Pads 2 per unit — one universal design fits all three oven sizes

Corner Posts 4 per unit — cookie-cut honeycomb adjusts to each size

Outer Carton 3 SKUs total: RSC for small unit; corrugated tray + HSC cover for medium and large

Three products. Three SKUs. One universal pad and corner design.

How the Design Hit Every Goal

• Eco-friendly: Honeycomb corrugated is recyclable and made from renewable materials.

• Protection: Cushioned top, bottom, and all four corners keep the ovens safe in transit.

• Cost effective: Fewer parts mean lower tooling, inventory, and storage costs.

• Easy to use: Snap off a section and drop in the unit. No guesswork. No extra tools.

• Fewer SKUs: One pad and one corner design replace six separate components.

• Less storage: Flat honeycomb pads stack tight. No bulky foam molds taking up warehouse space.

Need a Flexible Packaging Solution?

WynnPack specializes in custom packaging design for the Chicagoland region. We help manufacturers find smarter, leaner solutions — just like this one.

Whether you need EPS foam, honeycomb corrugated, wood crates, or molded pulp, we will design a system that fits your products and your budget.

Contact WynnPack today to discuss your packaging challenge.

wynnpack.com | Serving the Chicagoland area and beyond