A leading Packaging company approached Ingenious E-brain solutions to identify different aspects of optimization of secondary and tertiary packaging. Additionally, they asked us to identify key players in the packaging industry with similar technology.

Our Solution


There are three main levels of packaging which affects packaging and shipping of the products: the primary packaging, secondary packaging and tertiary packaging. Different packaging materials are used for various packaging purposes and have different functions.

Secondary packaging

Secondary packaging is mainly used for the logistical and branding display. Additionally, it is utilized to collect and protect individual units. Secondary packaging is also known as display or grouped packaging as they are made to display several units of products for sale. This facilitates resupply from the warehouse to the store and includes shelf-ready packaging (SRP), retail-ready packaging (RRP) or counter display units (CDU). These kinds of packaging are often used by the beverage, food and cosmetic sectors for displaying primary packs.

This type of packaging is significant for creating a brand image as it is often the first thing that the consumer sees. Thus, companies are working hard to make their products packaging more attractive and engaging, which reflects the real value of what’s the inside packet. Companies are following the latest packaging trends to differentiate their products from competence.

With a saturated and competitive market, products must divert customer attention from competing products, so companies are using secondary packaging to improve product visibility.

Tertiary packaging

Tertiary packaging is one of the three types of wrapping used to protect manufactured goods for shipping or storing. It is used to protect not only the product but also it’s secondary and primary packaging.

Tertiary packaging is typically not seen by consumers since retailers usually remove it before products are displayed for sale. Examples of tertiary packaging might include brown cardboard boxes, wood pallets and shrink wrap.


Opportunities in secondary and tertiary packaging optimization

There are many variables and solutions to optimizing secondary and tertiary packaging through the right selection of the materials such as testing the packaging; knowing the distribution cycle conditions and the products, etc. Here is a compilation of useful reference points to optimize the secondary and tertiary packaging given by our expertise:

  • Using sustainable and eco-friendly materials

– for the creation of the packaging

– to allow customers to recycle it

  •  Using innovative materials, such as bioplastics based on plants as a raw material instead of petroleum, which are applied in the substitution of films, cardboard and plastic bottles, among others.

Testing the materials, the packaging, unit loads or the products itself with transport simulation testing equipment leads companies to:

  • Redesign the packaging: an effective re-engineering of packaging cuts costs and waste while retaining brand benefits and consumer appeal. Furthermore, it allows companies to lower transport costs by resizing the size of the packaging to ship safely, optimizing the space in the chosen means of transport to the maximum.

– Reduce the use of stretch film by testing the unit load to optimize the packaging. This will contribute to reducing costs by reducing the use hours of the wrapping machine, decreasing the packaging waste and lower the CO2 emissions by reducing the weight of the load to be transported.

Solutions regarding the tertiary packaging process with transport simulation testing technologies

  • During the distribution cycle, goods are exposed to different forces that may affect their integrity and safety. These may be caused, for example, by acceleration, braking, handling or storing. These may result in severe consequences for the goods, and the way loads are secured. Transport simulation testing technologies enter the scene to foresee these threats.
  •  By using data obtained from a packaging transport simulation, it is, therefore, possible to design an optimized packaging tailored to real transportation conditions.
  •  This characterization should not only be applied to the packaging. Knowing the characteristics of the products will help companies to choose or design tertiary packaging to resist the stresses of the distribution cycle.
  • Some advantages of packaging transport simulation testing technologies include:
  • Complying with international transportation regulations and standards, such as those of the European Union, ISTA or ASTM.
  • Avoid economic lossesassociated with damaged goods during the distribution cycle.
  •  Optimize the packaging in a way that not only guarantees the safety of the products but is also the right one for them and the chosen route, eliminating unnecessary costs.
  • Transport simulation testing solutions.-Safe Load Testing Technologies solutions are characterized by their cutting-edge technology, intuitive use, and design. Besides, all of them meet a full range of test standards including ISTA, ASTM, ISO, EN or EUMOS, with the guarantee of maximum reliability and accuracy, simulating the reality in each test.


After the technology scouting, we provided our client with solutions of different processes, material and surface treatments in the optimization of secondary and tertiary packaging technologies that are currently in use in the packaging industry. Our scouting helps the client to start the R&D work. Also, we provided the list of assignee’s/competitors in the technology. 

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