Creating plastic packaging is not as simple as determining a nice shape or colour. Behind every bottle, cap, or container are many decisions that affect everything from price and purpose to sustainability and consumer appeal. At Coda Plastics, we’ve been serving companies for more than 40 years, assisting them in sidestepping these pitfalls, so we know where the pitfalls are - and how to avoid them.
Here are the five biggest plastic packaging design problems that we encounter, and the practical solutions that can actually make an impact.
1. Blending Cost with Quality
Every company wants packaging that looks great and performs well, but budgets are not infinite. The incorrect material or process can eat into profit levels very quickly.
We help clients balance the options. There are times when an off-the-shelf solution is the most cost-effective option. There are other times when a customised solution is the better investment because it increases efficiency or strengthens the brand. By tailoring the approach to the specific project, we keep budgets under control without cutting corners.
2. Meeting Sustainability Goals
Pressure is mounting from both consumers and regulators to reduce the environmental impact of packaging. But how can you achieve this without sacrificing performance?
We employ post-consumer recycled (PCR) plastics wherever possible. Through the use of 35-100% PCR material, customers can save tax and demonstrate genuine environmental concern - without undermining dependability. Our design experts also look at how best to reduce the total amount of material used, keeping packaging light and effective.
3. Protecting the Product
Packaging needs to be more than just visually appealing - it has to be safe, fresh, and secure in transport. Leaks, breakage, or contamination can be costly headaches for businesses.
Our manufacturing processes are designed with protection in mind. It could be airtight containers produced by injection moulding, leakproof roll on bottles produced by injection blow moulding, or tough jars produced by extrusion blow moulding. We use the right process for the task. The result is packaging that does what it’s supposed to: protect your product.
4. Standing Out on the Shelf
With so many competing products trying to grab shoppers’ attention, package design has to catch the customer’s eye straight away while still looking and feeling like your brand. Getting that balance right isn’t always easy.
Our designers work closely with clients to turn brand values into packaging that truly reflects their identity. From unique bottle forms to clear PET bottles that showcase the product itself, we create packaging that doesn’t gather dust on the shelf - it sells.
5. Lead Time Management
Being early to market can be as important as the packaging itself. Long lead times can impact your ability to get ahead of seasonal demand or get a jump on competitors.
Because we manufacture locally here in the UK, we can move fast. Standard lead times are as short as 4-5 weeks, and our Norfolk operation avoids delays typically linked to overseas supply chains. That gives customers the flexibility to stay responsive, respond to changing demand, and keep their products moving.
Final Thoughts
Plastic packaging design is full of challenges, but no challenge is too great to overcome. With the right partner, you can balance cost, sustainability, performance, and branding - and still deliver your product to market on schedule.
At Coda Plastics, we’ve been overcoming these challenges for decades. If you’d like to walk through your packaging requirements, our team is here to assist.