Packaging Unboxd is a podcast for packaging design enthusiasts who want to stay up-to-date on the latest trends and best practices. Hosted by Evelio Mattos, the Creative Director of Packaging Design, this podcast features insights from global experts on topics such as sustainable packaging, materials, manufacturing, and recycling. Listeners can learn how to create designs that are not only visually appealing but also environmentally responsible. Whether you're a packaging designer, engineer, or interested in making sustainable packaging choices.
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Stop choosing packaging sizes based on gut instinct instead of data and stop losing money on every shipment!Show Notes: (0:00) What is QuantiPack Ai(2:00) Packaging Efficiency(2:48) Save Millions(3:50) Who Is Karim Nammouz(5:50) ecommerce packaging(8:48) Building Quantipack Ai(10:12) Using Order Data To Save Money(12:34) Packaging Sales Using Quantipack Ai(16:09) Finding Money in your Data(18:04) Using QuadPack Ai(21:55) Saving $1.3 M(26:31) Packaging Optimization(32:20) How to Define Packaging Volume(34:34) Using Suite Analyzer(37:43) Packaging is SustainabilityIn this episode of Packaging Unboxd, we break down how most brands are unknowingly shipping air, overspending on materials, and missing massive opportunities to reduce cost and waste. Karim from Quantipack.ai reveals how packaging sizing audits powered by real order data can instantly uncover inefficiencies, improve fill rates, and drive both sustainability and profit. If you're a packaging designer, buyer, or engineer, this is the shift from guessing to knowing—where better math leads to better packaging, lower freight costs, and measurable environmental impact.
24 Feb 2026TRANSCRIPT
Why It Took 6 Years to Redesign This Box (Packaging Engineering Explained)
A “simple” candy box tweak turned into a six-year redesign—because in packaging, changing a quarter inch can force you to rethink the entire manufacturing line.00:00 Why a ¼-Inch Box Change Took 6 Years (Packaging Equipment)00:17 Charlotte Ashcroft Intro: Mike and Ike + Peeps Packaging00:47 What Is Packaging Engineering? Automation, Materials, Structure01:41 Mike and Ike Box Redesign: What Actually Changed02:52 Designing Packaging Backwards from the Pallet (Pallet Optimization)03:17 Headspace Explained: Damage, Settling, “Half-Empty” Complaints04:26 Hidden Carton Upgrades: Right-Sizing + Tamper-Proof Design07:49 Sustainability Wins: Fewer Trucks + Source Reduction11:38 Mike and Ike vs Peeps: Why “Gooey” Products Need Different Packaging14:02 3 Questions New Candy Brands Must Ask (Equipment, Shelf Life, Distribution)17:44 Shelf Life Testing: Chamber Studies + Packaging Barrier Basics27:20 EPR + SB 54: Recyclable Packaging Regulations + Real-World ImpactIn this episode with Charlotte Ashcroft, we unpack what packaging engineering really means—and why the stuff most designers never see (automation compatibility, headspace, pallet patterns, tamper-proofing, distribution reality) is where the real money, speed, and sustainability wins happen.You’ll learn:• What packaging engineering actually covers (beyond “structure”)• Why automation dictates more design decisions than people realize• The real reason “headspace” exists—and how it affects damage, complaints, and line speed• How engineers design backwards from the pallet (and why it saves trucks/material)• The hidden structural tweaks (glue, flaps, tamper-proofing) that change everything• How regulations like EPR / SB 54 push packaging decisions years in advanceIf you’ve ever thought “it’s just a box”… this one will permanently change how you look at packaging.Connect with Charlotte:LinkedIn:https://www.linkedin.com/in/charlotte-ashcraft/Packaging & Processing Women's Leadership Network:https://www.pmmi.org/womens-leadership-network/homeLarger Events:https://www.packexpoeast.com/https://www.packexpointernational.com/Support our Sponsor, and download your free Packaging Design Guide:https://idpdirect.com/design-guides/Connect with Evelio Mattoshttps://www.linkedin.com/in/eveliomattos/
12 Jan 2026
The Real Process Behind High-Impact Design for Startups
What does it really take to design packaging that connects, converts, and stands out... especially for a scrappy startup?In this episode of Packaging Unboxd, Evelio Mattos sits down with Monika Cascone, the designer behind the hilariously effective Anything Butt packaging. Learn more about Monika Cascone: https://www.monikacascone.comFrom working with tight budgets to building bold packaging strategies for taboo products, Monika shares the full behind-the-scenes process every young designer needs to hear.If you’re just starting your career in packaging or trying to figure out how to land your first freelance client, this episode is a blueprint. We cover what schools don’t teach you: managing clients, structuring your process, presenting multiple concepts, and staying flexible without compromising your creative value.Need to order custom retail packaging?Work with Evelio: https://idpdirect.com
Inside a recent episode
Saving $1.3M in Packaging
Published 18 Mar 2026 · Transcript excerpt
[…] Otherwise, you're gonna have a ton of excess space and try to condense that down. And I'm just thinking of the conversations that I have with the brands when we do this is like, what equipment are you filling with? Is it automated? Is it manual? Is it semi-automated? What particular equipment are you using? Because you're kind of limited in what that product packs out, right? So if it's like an auto bagger, it's like a tube and it's heat sealing and shipping them. Optimizing that is a little tough, but then it's also, if you recommend something different, now you've got investment for the brand of new equipment, new training, maybe a new facility, all those different things that tend to happen. […]
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