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Leverage 15 years of packaging design engineering experience for some of the top brands in the world
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40% of design projects fail
Project teams in FMCG companies often face challenges when developing new bottle designs. Common issues include:
Manufacturing Feasibility – Designs that look great in concept but pose issues during production.
Costly Redesigns – Late-stage changes due to unforeseen technical constraints.
Supplier Misalignment – Difficulty translating design intent into manufacturable solutions.
Time-to-Market Pressure – Tight deadlines leading to compromises on quality and efficiency.
Failure Rates
95% of NEW PRODUCTS FAIL **
60% PRODUCTS FAIL AFTER 3 YEARS**
70-90% FAILURE RATES FOR CPGs
60% NEVER MAKE IT TO MARKET
95% of NEW PRODUCTS FAIL ** 60% PRODUCTS FAIL AFTER 3 YEARS** 70-90% FAILURE RATES FOR CPGs 60% NEVER MAKE IT TO MARKET
Solution
Early application of DFM requirements in the design phase reduces project issues, while maintaining time lines and cost overruns.
I provide expert bottle design support to ensure your packaging is not only visually compelling but also optimized for manufacturing from the start. My approach includes:
DFM Expertise – Designing bottles that work seamlessly within your existing production capabilities.
Supplier Collaboration – Bridging the gap between design teams and manufacturers.
Technical Problem-Solving – Identifying and resolving potential production challenges before they become costly issues.
Efficient Development – Helping you reduce time to market with manufacturable, high-quality designs.
Risks without Design Engineering:
Early 2D Evaluation
Sharing 2D concepts that look great but aren’t manufacturable can create emotional buy-in around unfeasible designs, leading to costly rework, delays, or even project failure. Early DFM checks help avoid wasted effort by aligning teams around concepts that can actually be produced.
3D Concept Evaluation
When 3D concepts aren't properly evaluated for DFM requirements, critical issues like volume, label area, or other supplier constraints can be missed. This can lead to delays, or costly last-minute changes—putting launch timelines and product performance at risk.
Bottle Design Development
As an SME in 3D packaging design engineering across categories like Skin Care, Deo, Dressings, and Ice Cream, there’s little I haven’t seen or solved. Bringing me onto your project means fewer surprises and a smoother path to a production-ready design.
Benefits of Working with Me:
Early 2D Evaluation
With deep expertise in both design and engineering, I bridge the gap between creative vision and manufacturing reality. By grounding early concepts in DFM principles, I align teams around viable ideas—reducing risk and building momentum from the start.
3D Concept Evaluation
I help catch issues early, ensuring smoother production and minimizing costly delays or redesigns. I deliver production-ready packaging that looks great, functions flawlessly, and gets to market faster—with fewer surprises.
Bottle Design Development
I provide expert oversight at any phase of the bottle design process, ensuring supplier alignment while safeguarding the original design intent—streamlining collaboration and reducing friction between design and manufacturing. With the ultimate goal of getting the bottle to market.
How it Works:
Consulting
I begin by understanding your project’s needs, aligning on design goals, technical requirements, and manufacturing constraints. This ensures a clear direction and a strategic approach tailored to your brand’s objectives.
The Work
With a defined strategy, I analyze and refine packaging solutions that balance creativity with engineering feasibility. I leverage my expertise in design, materials, and manufacturing to create functional, high-quality packaging.
Successful Launch
I deliver production-ready designs, complete with technical specifications and manufacturing guidance. My goal is to ensure seamless execution, reducing risks and accelerating time to market.
Packaging Design Engineering Services:
2D Concept Evaluation
The 2D concept evaluation ensures early design compliance with DFM by identifying non-compliant visual features.
3D Concept Evaluation
3D CAD files are analyzed to ensure they meet manufacturing requirements, including volume, label, overall dimensions, and other supplier-specific criteria.
Bottle Design Development
I can manage your agency's bottle design at any phase, aligning with supplier requirements while maintaining the design intent.
Packaging Design Solutions:
Early 2D Evaluation
Analyzing 2D to stay ahead of issues
Line and Shelf Stability
Top Load stability for capping
Label-ability of the surface
What could the fill level look like
Cap Bottle integration
3D Concept Evaluation
Evaluate 3D CAD files for DFM inconsistencies
9 point quick inspection
Label analysis
Volume checks
Molding analysis
Customer Requirements
Bottle Design Development
Bottles built from scratch to meet DFM requirements
Build DFM compliant 3D files
Bottle opimization
Downsizing bottles
Create 2D drawings
Molding analysis
The Numbers:
The data on failure rates of projects going to and in market, commonly cited high failure rates are overestimated
indicating that the actual product failure rate is around 40%.
(Source: the Journal of Product Innovation & Management)
Packaging Launch Rate:
Only 40% of developed products actually make it to market,
implying that 60% of product designs do not reach commercialization.
(Source: G2's Learning Hub).
Market Success Rate:
Up to 80% of new FMCG products fail within their first year.
(Source: Nielsen, Harvard Business Review).
90% of packaging redesigns fail to deliver meaningful results
Due to insufficient consumer testing during critical stages.
(Source: Amati and Associates)
Approximately 95% of the 30,000 new products introduced annually fail.
Early application of DFM allows design changes to be executed quickly and at a lower cost,
(Source: MIT Professional Education)
Failure rates for new products in the Consumer Packaged Goods (CPG) industry range between 70% and 90%
(Source: FoodNavigator-USA)
A study analyzing nearly 9,000 new products with national retail distribution found that only about 40% remained available three years post-launch
indicating a 60% failure rate
(Source: MIT Sloan Management Review).
Design Drives Manufacturing Costs:
70% of manufacturing costs are determined by design decisions.
Early application of DFM allows design changes to be executed quickly and at a lower cost,
(Source: East West Manufacturing)
Manufacturing & Engineering-Related Delays & Overruns:
it's well-documented that inadequate attention to design and engineering often leads to project delays and overruns.
McKinsey reports that insufficient focus during early phases results in high levels of change orders, directly affecting project timelines.
(Source: McKinsey report)
What can be done to reduce the risk of design project failures?
Ensure projects include concept validate 2 & 3D data in accordance to manufacturing requirements
** Sources: Harvard Business School, MIT Professional Education, FoodNavigator USA, Amati and Associates and McKinsey