Considerations for Packaging Risk Assessment

As costs, consumer expectations and regulatory requirements continue to increase, having a thorough understanding of potential risks to a brand’s product and its packaging is essential. A thorough packaging risk assessment is a critical step to assuring quality and safety of both the product and the package.

A packaging risk assessment is a process used to evaluate potential risks associated with packaging materials and designs. This blog covers important factors related to potential regulatory concerns, material hazards, product stability issues, transport and handling risks, and ergonomics and user safety. A follow-up blog will cover additional factors, including environmental impact, supply chain challenges, quality assurance and important documentation and communication.

Regulatory Compliance

A good first checkpoint is a review of relevant regulations and packaging’s compliance status. This includes international, national and local regulations that govern packaging in the jurisdictions where the product is sold. Confirming compliance not only covers a brand’s legal requirements, but also ensures products and packaging are safe for consumers.

Many packaging regulations are intended to ensure packaging materials don’t pose risks to consumers and that products remain safe as they move through their distribution environment. Other regulations mandate that labeling and other print accurately convey product information, nutritional facts, ingredients, allergen warnings and other details. A growing category of regulations addresses sustainability, promoting eco-friendly packaging and responsible disposal at the end of the package’s life.

Non-compliance exposes brands to risk of reputational damage, costly recalls and potential fines. As regulations vary from jurisdiction to jurisdiction, ensuring compliance requires a broad base of knowledge for products distributed internationally.

Material Selection

The materials a brand chooses for its packaging are pivotal. Selections must account for product compatibility, preservation and protection against hazards the package may encounter in its distribution environment. Factors such as chemical resistance, moisture barriers and structural integrity play a crucial role in preventing contamination and protecting against damage.

Choosing eco-friendly and responsibly sourced materials reduces environmental impact and helps brands meet their sustainability goals. Recycled, recyclable, reusable and biodegradable or compostable materials help brands meet consumer and regulatory demands for sustainability.

Packaging place a central role in shaping and reinforcing a brand’s image. Premium material choices can convey quality and exclusivity, while sustainable choices can enhance a brand’s reputation, especially with younger consumers. Unique materials can help a product stand out from the competition on retail shelves.

Selecting the right materials can optimize production and shipping costs. Lightweight, durable materials can reduce expenses and environmental footprint. Easy to open, aesthetically pleasing and functional materials can enhance consumer satisfaction.

As the choice of packaging materials impacts so many brand priorities, reviewing these factors thoroughly helps to protect against competitive, financial, reputational and legal risks.

Hazard Identification

Identifying potential hazards associated with packaging materials is another important consideration when assessing risks. Evaluating the likelihood and severity of potential issues such as sharp edges, toxic substances and flammable components helps packaging teams determine the level of risk they pose. For example, it’s important to know if chemicals in packaging materials could potentially migrate into food items. For products containing allergens, proper hazard identification is essential to prevent cross-contamination during packaging, especially for brands in the food and pharmaceutical industries.

Hazard identification is mandated by health authorities and regulatory agencies worldwide. Failure to identify and address hazards can lead to violations, fines and other legal consequences. To mitigate against potential reputational damage, financial consequences, hazard identification must be an integral part of the packaging design and production process.

Product Stability

Packaging serves as the first line of defense against external factors such as exposure to light, moisture and oxygenation, all of which can degrade the quality of certain products. By assessing stability risks, packaging teams can choose materials and designs that effectively protect the product against these factors. In some industries, such as pharmaceuticals and food, product stability is directly linked to safety. Packaging failures can lead to contamination or spoilage, posing health risks for consumers. A thorough understanding of stability risks helps ensure consumer safety and regulatory compliance.

Consumers expect products to maintain quality and freshness until they use them. Packaging that doesn’t adequately address stability concerns can result of disappointed customers, damaging brand reputation and potentially losing consumers to competitors in the marketplace.

An accurate evaluation of stability risks helps packaging teams avoid over-packaging and using materials/designs that are more expensive than necessary for the product’s stability needs, a significant source of excess cost. Knowing the risks helps packaging designers strike the right balance between protection and cost in addition to avoiding excess packaging waste, enabling more sustainable choices.

Transport and Handling

Packaging is the primary safeguard against damage for products during transportation and handling. Assessing risks in the distribution environment helps ensure that the packaging can withstand stresses such as shocks, vibrations and temperature fluctuations, safeguarding the product's integrity. Inadequate packaging can lead to product damage or losses in transit, resulting in unnecessary costs. Consumers expect the product to arrive in good condition, and failure to meet that expectation negatively impacts their experience with the brand and its product.

Packaging that is not designed to handle the rigors of transport and handling can slow down supply chains, and delays caused by damaged products or the need for additional protective measures can be costly. Damaged products often lead to waste from replacement or repair and reverse logistics, which have environmental consequences. Packaging that accounts for transport and handling risks reduces this waste and promotes sustainability.

Ergonomics and User Safety

Packaging must be user-friendly and safe, including aspects such as ease of opening, clear handling instructions and, when necessary, child-resistant features. Packaging that causes frustration or, worse, injuries are a risk to a company’s reputation. When consumers associate a brand with frustrating or unsafe packaging, they lose trust and are more likely to look else when in the market for similar products in the future.

Ergonomically designed packaging enhances users’ experience and easy-to-open, user-friendly designs promote consumer satisfaction and loyalty. Beyond safety, assessing and addressing ergonomics and safety risks helps brands mitigate against liability. By taking proactive measures to ensure safety and ease of use, packaging teams can reduce the likelihood of injury-related lawsuits. Investing in safe, ergonomic packaging may seem like an upfront cost, it helps brands save money in the long run by reducing the risk of product losses and legal fees.

If your brand is experiencing challenges related to these packaging risks or needs help evaluating potential risks for a new packaging product, Adept Group can help. Our nationwide team of packaging experts has experience helping brands overcome every type of packaging challenge efficiently, providing effective results and driving cost savings. Get in touch.