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PackBase — e-commerce Packaging Studio

Smart protective packaging for online brands

Packaging engineered for e-commerce — protection, branding, and logistics efficiency

We specialise in packaging systems that reduce transit damage, optimise dimensional weight, and amplify the unboxing moment. Our process begins with a product survey and a fulfillment audit: we measure, weigh, and observe how products are packed today, then model improvements that lower shipping cost and increase protection. Structural design work balances cushioning performance with right-sizing to avoid unnecessary volume. Branding decisions—from printable panels to tactile finishes—are assessed through the lens of fulfilment speed and recyclability so your packaging looks premium without becoming wasteful or fragile.

For subscription brands, marketplaces and direct-to-consumer retailers we create integrated kits: single-item mailers, multi-part packouts, returnable systems and sustainable filler alternatives. We advise on regulatory labeling, retail-ready sleeves, and e-commerce-friendly closures that speed automated packing. Our studio produces functional prototypes, small pilot runs and scalable production so packaging supports business growth from seed stage through broad distribution.

ecommerce packaging samples

Advantages — what distinguishes our packaging approach

Each advantage below is developed with measurable outcomes in mind: lower damage, lower freight cost, and improved customer experience.

advantages visual

Right-sizing & Freight Efficiency

We model volumetric weight and package geometry against your carrier contracts and typical basket mix so you ship fewer cubic centimetres and pay less per order. Right-sizing reduces wasted space in trucks and lowers dimensional weight surcharges—two often overlooked cost drivers. Our engineers use parametric packing logic to suggest box sizes that accommodate multiple SKUs without overspecifying void volume, and we test iterations to find the best compromise between protection and parcel footprint.

Protection & Damage Reduction

Material science informs our cushioning systems: tailored flute selection in corrugated board, engineered moulded pulp supports, or low-profile honeycomb inserts when shock and compression resistance are needed. We pair finite element drop testing with empirical trials to validate solutions. Packages are designed to prevent movement, avoid point loads on delicate components, and resist typical courier handling. The result is fewer returns, less rework and a better experience for end customers.

Sustainable Material Pathways

Sustainability is integrated early in material selection. We prioritise recycled fibreboard, certified compostable liners, mono-material constructions for easier recycling, and minimal ink surface area without sacrificing brand impact. When plastics are necessary, we specify fully recyclable grades and design for separation at end of life. Our team provides end-of-life guidance and can support take-back or refill programs that transform packaging from single-use to part of a circular flow.

Fulfillment & Automation Compatibility

Packaging must work in real warehouse conditions. We design closure systems, tuck patterns and labelling zones that integrate with packing stations and automated label printers. Barcodes, return labels and peelable tamper tapes are considered in every dieline to prevent manual rework. Our design files are delivered with cut files and print specs so your fulfilment provider can implement without delay, and we advise on packing ergonomics to reduce time per order in high throughput environments.

Branding that Unboxes Well

The unboxing sequence is a strategic brand moment. We design printed panels, insert layouts, and consumable elements (stickers, tissue, thank-you cards) that create delight while still being fulfilment-friendly. Options range from single-colour economical print to multi-pass premium finishes. Where tactile cues matter we specify embossing, subtle varnishes, or low-impact soft-touch coatings that preserve recyclability when chosen correctly.

Prototype, Pilot & Scale Support

We support the full productization pathway: rapid prototyping for design validation, short pilot runs to test consumer response and fulfillment behaviour, plus scalable production plans. Our vendor network spans digital print partners for low minimums and rotary facilities for higher-volume runs, enabling smooth transitions as order volumes grow.

about our studio

About the Studio — multidisciplinary packaging for online-first brands

We are a cross-disciplinary team of structural designers, material scientists, print technologists and logistics advisors focused exclusively on the unique constraints of e-commerce. Unlike general packaging houses, our studio approaches each brief with fulfilment realities in mind: carrier rules, dimensional weight, return logistics and batch handling. Our clients include subscription services, apparel brands, home goods sellers and electronics vendors who need packaging that performs both visually and operationally.

Early in our method we perform a fulfilment audit — observing live packing lines, measuring common order combinations and recording failure modes. Using that intelligence we create dielines, select board grades, and prototype inserts. These prototypes are subjected to drop, vibration and compression tests aligned with courier profiles and then iterated based on results. We document all decisions and produce handover packs for production partners so scaling remains predictable.

We also advise on cost modeling and supplier selection. Packaging is rarely the single largest cost line, but small per-unit savings compound fast across many shipments. Our recommendations aim to reduce total landed cost while maintaining protective performance and brand quality.

Services — what we deliver for e-commerce teams

From concept to continuous production support, choose a service path that matches your stage.

services overview

Structural Design & Dielines

Tailored box and insert designs that secure products while optimising material usage. Deliverables include CAD dielines, cutting files, and nesting plans for efficient sheet utilisation.

Material Consulting & Sustainability Planning

Guidance on fibre grades, compostable options, and mono-material strategies. Life-cycle considerations and end-of-life recommendations aligned to your customer's recycling infrastructure.

Prototyping & Performance Testing

Rapid prototyping using digital and analogue tooling, drop and compression testing, and iterative refinement based on lab and field trials.

Pilot Runs & Supplier Qualification

Low-minimum print and production runs for market validation, plus supplier audits and sample packs to ensure production consistency.

Fulfilment Integration

Implementation support for pack station ergonomics, label placement, returns handling, and automation compatibility. Training materials for operations teams included.

Lifecycle Management & Continuous Improvement

Ongoing performance tracking, damage analytics and seasonal adjustments to packaging strategy so materials and specifications evolve as volumes change.

Contact & Local Office (Florence)

For samples, quotes and production planning contact our local team for a preliminary fulfillment audit and sample pack.

Address:
V.le Filippo Strozzi 1, 50129 Firenze FI, Italy
Hours:
Mon–Fri: 09:00 — 18:00 (local time)

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