Lean Design for Sustainability

When designing packaging, creativity often meets a hard reality—manufacturers have limitations based on their machines. Many packaging machines are built for high-volume production, with fixed size constraints and bulky setups. This can make it difficult to produce smaller packaging with tight tolerances, limiting design possibilities.

In the past, I had complete freedom by producing my own die-cut shapes. This allowed me to explore innovative packaging solutions without being restricted by external production requirements. However, I quickly realized that this level of customization made it nearly impossible to scale production with external manufacturers.

More importantly, I discovered a key sustainability challenge: the more specialized a box is, the fewer opportunities it has for reuse. Custom packaging may look impressive, but it often serves a single purpose before being discarded. In contrast, simple and modular designs—like a classic telescope box—offer greater longevity. These boxes can be repurposed by the end user in countless ways, reducing waste and extending their lifecycle.

By applying lean product development principles, we can design smarter, more adaptable packaging that works within existing manufacturing constraints while prioritizing sustainability. Instead of overcomplicating designs, focusing on versatility, recyclability, and material efficiency leads to packaging that is both functional and environmentally responsible.