Protective packaging is a form of insurance: You invest in it to reduce risk further down the line. The primary goal of protective packaging is to prevent product damage which saves your business money, protects your brand and improves the unboxing experience for the end customer.

Custom protective packaging designed and manufactured by PPI can be trusted to prevent product damage. We design fully recyclable packaging uniquely capable of protecting products, even when those products are oddly shaped or particularly fragile. Request a consultation with us now to find out how we can provide the perfect packaging solution for your product.


When it comes to protective packaging, we’re the experts

We’ve been creating custom designed packaging for Australian businesses since 1980. In that time, we’ve built a team of specialist designers, engineers, and technicians who combine a wealth of knowledge with a ‘think outside the box’ attitude to help bring your protective packaging solution to life. We are committed to meeting your needs and ensuring your products are well protected, enabling them to reach your customer with no nasty damages that will affect your brand reputation and bottom line.

Types of protective packaging

  • Standard style shipper cartons
  • Fully customised cut to shape boxes
  • Product specific inserts
  • Protective inserts
  • Branded or plain

Important Considerations for Customised Protective Packaging 

To achieve its purpose, all custom designs for protective packaging must keep the product needs at the forefront. Overweight and bulky products will require different design functionalities compared to fragile, easily breakable products. Protective packaging demands customisations to be put in place so it can guard the product throughout the logistics journey.

  • Pick the right materials 

Whether it’s make-up, food, dish cleaning liquid or a piece of furniture – each requires protection from different environmental factors. In addition, given their shape and size – they need differing degrees of support to withstand the impacts of transport and handling. 

In protective packaging – there is no one size/type that fits all. Picking the right material is the key to ensuring that the product reaches its final destination in the intended condition.  

The right packaging material will offer the kind of support the product requires, whether it’s to sustain the freshness of food items with limited shelf life or heavy pieces of electronics that will likely be staked together – having to ensure one-another’s weight. 

PPI’s specialisation in sustainable packaging allows us to create custom protective packaging for you, that’s also eco-friendly while being sturdy enough to offer the kind/extent of protection needed by your product. 

  • Be specific about product specifications 

Packaging shouldn’t be too big for the product – that causes wastage of materials and other resources. Most successful custom designs for protective packaging fit the product snug like a glove! Therefore, dimensions are extremely important when it comes to custom protective packaging.  

Designers must have the correct measurements to create packaging that fits the product well – not too big, nor even slightly small. This not only helps avoid wastage but also ensures that the product will stay in place despite the impacts during transportation. 

In custom design packaging boxes, you can limit the movement of the product by minimising the extra space. This helps prevent the possibilities of damage during handling and delivery, thus, helping your business save on the costs associated with damaged goods while also ensuring your customers are always happy with what they receive.


FAQs about Protective Packaging Solutions


Does protective packaging include inserts and cushioning? 

Yes. Outer protective packaging ensures the product remains sealed and unexposed to external damages. While the inserts are put in place to minimise the movement and protect the product from ruining inside the box while in transit. Both measures collectively help businesses save on costs of damaged products and meet customer satisfaction.

What are some of the materials commonly used to make protective packaging? 

Depending on the packaging needs of the product and environmental concerns, custom packaging designs are created using a range of materials. Such as corrugated cardboard, molded pulp, air pillows, bubble wrap and foam.

Does branding play a role in protective packaging? 

Branding is essential on protective packaging because it communicates with the consumer before the product itself. It enables brand recognition, which, over time, increases customer’s affinity towards the brand and its products. Thus, leading to repeat purchases. Advancement in design and production allows packaging experts to develop custom packaging boxes that meet all criteria’s for protection, as well as are a great unboxing experience on the receiving end.  

Protective packaging case studies and articles

Case study

IXL Appliances

IXL Appliances is an industry leader and innovator in home appliances. Since 1858, IXL has been synonymous with the highest quality heat, light and ve...

Production Packaging Innovations designed protective inserts for IXL Appliances’ iconic Tastic bathroom heat lights and saved IXL thousands in future damaged products.

Case study

Case Study – Ned Australian Whisky

Ned Australian Whisky is an Australian whisky for everyone. Born from a desire to create a locally crafted whisky that’s unqiuely Australian, Ned Wh...

PPI created custom protective packaging for Ned Australian Whisky, a premium whisky distilled in Campbellfield, Victoria.


5 Protective Packaging Tips for Your Products

In a world where leaving a product review is only a few clicks away from a smartphone, it’s vital for your products to arrive on your consumers’ d...


Our capabilities & process

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