Briefly |
THE SCALE OF PACKAGING DECISIONS
Selling 1 to 2 million phone cases annually makes packaging a massive lever for cost and waste reduction. For BURGA, our goal was to elevate shelf presence while optimizing for cheaper, faster packing. At this volume, minor structural and material changes save tons of waste and hundreds of thousands of euros.
Maximum optimization 150+ products and only 2 insert sizes
Chapter 1 |
PROJECT GOALS
With over 300 designs and 150 models, BURGA needed a highly adaptable, scalable packaging solution. To solve the logistical and retail bottlenecks of the previous design, the overhaul focused on four key areas:
Scalability & workflow: We replaced wasteful, poorly fitting foam inserts with a smooth-sliding inner structure to speed up manual packing and reduce the storage footprint.
Retail visibility: The old black packaging and glare-heavy plastic windows obscured the product. The new design exposes the side buttons and frees the front for clear information.
Sustainability: We eliminated the unrecyclable material sandwich of plastic windows, foam cores and hooks, together with its expensive manufacturing waste.
Brand ecosystem: The structural direction can scale across BURGA product lines, including laptops, earbuds and drinkware.
Chapter 2 |
DEVELOPMENT PROCESS & SOLUTIONS
Field research & workflow: Together with the BURGA team, we observed warehouse fulfilment firsthand and designed a frictionless assembly process for packing staff.
Engineering the adaptive wings: Paper prototyping produced an insert with technical-paper wings that flex for different phone models and lock each product in place without foam.
The organic B cut-out: A B-shaped opening replaced the plastic window, letting customers touch the product and inspect its side buttons on the shelf.
Mono-material finalization: The design became a 100% paper solution with an integrated paper hook, and three packaging sizes were reduced to two.
Chapter 3 |
UNBOXING EXPERIENCE
We replaced the traditional window with an organic B cut-out, maintaining structural strength while allowing customers to touch and see the product and its side buttons.
A dedicated key-information area on the front lets customers find the most important product information at a glance.
The packaging uses 100% paper with a water-based soft-touch finish for a pleasant, premium feel that remains recyclable.
Chapter 4 |
SOLUTIONS & RESULTS
Quantity of inserts for 150+ products
A fixed EVA foam structure restricted phone-case size adaptability.
Just 2 insert sizes
Insert material
Plastic foam: wasteful, non-recyclable and unpleasant smelling.
Engineered paper with adaptive, recyclable wings.
Visibility of the product
Glossy plastic scratched and reflected glare; side buttons were hidden.
The B cut-out allows direct touch and shows the side profile.
Recyclability
Multiple materials were difficult to sort.
100% paper enables one-bin disposal.
On-pack information
Information appeared only on the back.
A dedicated key-point area sits on the front.
Hanger
Plastic Euro hook.
Integrated paper hook.
Regulations and taxes
Subject to multi-material waste taxes.
Future-proofed for lower eco-tax tiers.
Surface finish vs recyclability
Soft-touch laminate.
Water-based soft-touch varnish.
HOW IS IT FUNCTIONING IN THE RETAIL
100% mono-material paper solution
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