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 Packaging
00:47 What Is Packaging Engineering? Automation, Materials, Structure
01:41 Mike and Ike Box Redesign: What Actually Changed
02:52 Designing Packaging Backwards from the Pallet (Pallet Optimization)
03:17 Headspace Explained: Damage, Settling, “Half-Empty” Complaints
04:26 Hidden Carton Upgrades: Right-Sizing + Tamper-Proof Design
07:49 Sustainability Wins: Fewer Trucks + Source Reduction
11:38 Mike and Ike vs Peeps: Why “Gooey” Products Need Different Packaging
14:02 3 Questions New Candy Brands Must Ask (Equipment, Shelf Life, Distribution)
17:44 Shelf Life Testing: Chamber Studies + Packaging Barrier Basics
27:20 EPR + SB 54: Recyclable Packaging Regulations + Real-World Impact
In 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 advance
If 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/home
Larger 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 Mattos
https://www.linkedin.com/in/eveliomattos/
