Where Student Innovation Meets Real-World Packaging

At PSI, we believe in investing in the future of packaging—both through innovation and education. For the second year in a row, we were proud to collaborate with Virginia Tech’s Packaging Systems and Design department on their senior capstone course, Packaging Systems Design Practicum.

As part of the capstone experience, a team of five talented Virginia Tech seniors—Austin Byrd, Clarissa Miller, Greg Greiner, Javar Saunders, and Natalie Lainhart—tackled a real-world packaging challenge sponsored by PSI. The students were tasked with designing a sustainable, e-commerce-ready packaging solution for a 7-piece stainless steel cookware set from one of our customers—a leading premium cookware brand.

Left to right: Molly Trinh, Natalie Lainhart, Javar Saunders, Greg Greiner, Austin Byrd, Clarissa Miller

The Challenge:

The design requirements were demanding. The packaging had to meet strict sustainability goals (no plastic, foam, or void fill), pass ISTA 6A testing procedure, fit efficiently on a standard pallet, be easy to assemble, and elevate the customer unboxing experience—all while protecting high-end stainless steel cookware during transit.

The Design Journey: Prototyping, Testing, and Iterating

With PSI’s real-world requirements and the brand’s premium standards as their guide, the student team began by analyzing leading cookware packaging to understand trends in sustainability and design. Their research revealed a growing trend toward minimalist, sustainable packaging in the cookware market—but also showed areas where they could improve the brand’s current packaging in terms of efficiency and environmental impact.

The team kicked off the creative process with hand sketches, structural mockups, and CAD drawings. To ensure precision, the team visited PSI to use our 3D scanner, capturing exact measurements of the cookware before building their first physical prototype. The initial design, though conceptually strong, failed drop testing due to lack of insert support—highlighting the delicate balance between minimal materials and maximum protection.

Refining their approach, the students revised their insert design and adjusted the flute type for better strength and material efficiency. Their second prototype used lighter E-flute inserts to reduce cost and improve print quality, but it didn’t hold up in testing. This setback reinforced key lessons in balancing structural integrity with sustainability, prompting the team to further strengthen their solution.

For the third and final prototype, the students landed on a 32 ECT C-flute corrugated solution that offered the right combination of structural integrity, protective cushioning, and ease of assembly. They also redesigned the opening experience by integrating perforations and thumbholes to make unboxing smoother and more intuitive.

The Result:

The students developed a custom-designed corrugated packaging system using a two-part 5-panel folder and layered inserts, carefully engineered for structure, sustainability, and ease of assembly. Their design featured:

• SIPP-compliant construction

• 100% corrugated materials with no plastic or foam

• A significant reduction in material usage compared to the brand’s existing packaging

• Custom insert graphics and an included recipe card for a premium unboxing experience

• Improved pallet efficiency and reduced packing time (under 10 seconds per item)

This collaboration reflects PSI’s ongoing commitment to sustainable innovation, industry education, and solving real-world packaging challenges. We were impressed by the students’ creativity, technical abilities, and adaptability as they navigated constraints and refined their designs. Special thanks to Dr. Robert Bush and Dr. Matt Baker of Virginia Tech, and PSI designer Molly Trinh, for their mentorship and support throughout the project. We’re especially proud to welcome team member Greg Greiner to PSI as a full-time Packaging Engineer—a testament to the strength of this partnership and the bright future of packaging design!