Redesigning Packaging Efficiency for Lux Nitro Innerwear

Challenge:

Lux, a well-known manufacturer of inner garments, was facing operational hurdles with its Nitro range of men’s vests.

The product packaging used FFT (Full Flap Top & Bottom) boxes, which presented multiple challenges:

1. High Labor Dependency – The FFT structure was complex and required more time and effort to assemble.
2. Increased Packing Time – Each box took longer to form, slowing down the production and packing process.
3. Elevated Packaging Costs – The packaging design and labor-intensive process led to higher overall costs.

Solution:

Canpac’s packaging experts re-evaluated the box structure and offered a simple yet impactful change:

1. Retain the FFT Top for brand consistency and structural appeal.
2. Redesign the Bottom to a Four-Corner Style, which is easier and quicker to form.
3. This hybrid structure offered the best of both worlds—maintaining the look and functionality of FFT on top, while simplifying the bottom to optimize labor and cost.

Results:

• Reduced Assembly Time – The four-corner bottom design significantly cut down forming time
• Lower Labor Involvement – Easier assembly meant fewer hands needed on the packing line
• Improved Operational Speed – Faster box formation increased overall productivity
• Cost Reduction – Packaging cost dropped by approximately 20%

Impact:

With this design shift, Lux Nitro’s packaging process became leaner and more cost-efficient without compromising product presentation. By simplifying just one element—the box bottom—Canpac helped Lux unlock significant savings and operational ease, setting a new standard for future packaging decisions.