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 Packaging00:47 What Is Packaging Engineering? Automation, Materials, Structure01:41 Mike and Ike Box Redesign: What Actually Changed02:52 Designing Packaging Backwards from the Pallet (Pallet Optimization)03:17 Headspace Explained: Damage, Settling, “Half-Empty” Complaints04:26 Hidden Carton Upgrades: Right-Sizing + Tamper-Proof Design07:49 Sustainability Wins: Fewer Trucks + Source Reduction11:38 Mike and Ike vs Peeps: Why “Gooey” Products Need Different Packaging14:02 3 Questions New Candy Brands Must Ask (Equipment, Shelf Life, Distribution)17:44 Shelf Life Testing: Chamber Studies + Packaging Barrier Basics27:20 EPR + SB 54: Recyclable Packaging Regulations + Real-World ImpactIn 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 advanceIf 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/homeLarger 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 Mattoshttps://www.linkedin.com/in/eveliomattos/

What does it really take to design packaging that connects, converts, and stands out... especially for a scrappy startup?In this episode of Packaging Unboxd, Evelio Mattos sits down with Monika Cascone, the designer behind the hilariously effective Anything Butt packaging. Learn more about Monika Cascone: https://www.monikacascone.comFrom working with tight budgets to building bold packaging strategies for taboo products, Monika shares the full behind-the-scenes process every young designer needs to hear.If you’re just starting your career in packaging or trying to figure out how to land your first freelance client, this episode is a blueprint. We cover what schools don’t teach you: managing clients, structuring your process, presenting multiple concepts, and staying flexible without compromising your creative value.Need to order custom retail packaging?Work with Evelio: https://idpdirect.com

Walk through the top 7 Packaging Design Trends You Need to Know for 2026!Work with Evelio, https:www.IDPdirect.comPackaging design is changing fast and most trend reports are already behind.In this episode, I break down the real packaging design trends for 2026 based on what’s actually showing up on shelves around the world, conversations with agency leaders, manufacturers, and global brands. If you’re a packaging designer, graphic designer, brand founder, or marketer, this video will help you understand how to design packaging that survives manufacturing, regulation, cost pressure, and real consumer behavior.These trends aren’t about copying looks. They’re about understanding why packaging is changing and how to use that knowledge to build stronger brands.What You’ll Learn in This Video• The top packaging design trends for 2026• How inflation, GLP-1 drugs, and regulation are reshaping package size and format• Why plastic is coming back (and how to design it without making it feel cheap)• How designers are fighting AI sameness with human chaos• Why structure matters more than graphics in premium packaging• How to use color to stop shoppers at six feet, not two• Why regulation-ready packaging is becoming a competitive advantage• When to use trends and when to ignore them entirely

In this episode of Packaging Unboxd, host Evelio Mattos tears down the influencer packaging that made Daise Beauty a must-watch unboxing moment across social media.

Discover how smart brands design packaging not for the shelf, but for the camera, building FOMO, shareability, and lasting brand awareness through structure and storytelling.

Evelio breaks down what Daise Beauty did right, what every influencer box needs, and how to design packaging that becomes content.

You’ll learn:

• The structural secrets behind influencer kits that go viral

• How to layer unboxing moments for maximum retention

• Why print finishes, materials, and afterlife design matter

• How to turn a PR box into a media campaign

Perfect for packaging designers, brand managers, and creative directors who want to make their next unboxing unforgettable.

🎧 Listen now on Packaging Unboxd with Evelio Mattos.

Work with EVELIO MATTOS www.IDPdirect.com

After 30 years running a successful studio shooting global brands, Terri did the unthinkable, he shut it all down.

Why? Because AI changed everything.

In this episode, we explore how one veteran creative reinvented his entire career, turning decades of experience in photography and design into an AI-powered workflow that’s faster, sharper, and creatively free.

Learn what it really takes to pivot from traditional design to AI-driven creation, and why the next generation of designers might not pick up a camera ever again.

You’ll Learn:

• Why AI became the turning point after 30 years in business

• How photography skills transfer to AI image generation

• The real creative value behind “prompting”

• How brands are responding to AI-made visuals

• The future of design studios in the age of AI

DM Evelio to design your packaging: https://www.linkedin.com/in/eveliomattos/Are you making these packaging design mistakes?In this episode of Packaging Unboxd, 13 of the world’s top packaging designers from New York, London, Melbourne, and beyond share the worst packaging design mistakes they still see and exactly how to avoid them.If you're a young packaging designer, a freelance creative, or a startup founder designing your first product, this episode is your playbook to avoid common (and costly) design errors. From bad color contrast to category code overkill, to Pantone and Adobe color licensing fails, these are the real mistakes killing shelf impact and brand success.

Let's design your packaging -   / eveliomattos  Download the tools to design your own packaging - https://idpdirect.com/design-guides/Can packaging made of 90% air actually outperform traditional plastic foams—and still be recyclable and compostable? Sustainable Development Packaging from Woamy should be on your list of trending packaging design materials for 2025.In this episode of Packaging Unboxd, host Evelio Mattos dives into the deceptively simple yet groundbreaking world of sustainable foams with the founders of Woamy. This isn’t your typical “green” material. Woamy has developed a foam that mimics the directional strength of wood, is crafted entirely from FSC-certified cellulose, and is held together with water. No glues. No plastic. Just air and pulp.We unpack how layering this material changes everything from load-bearing strength to flexibility, making it a top contender for replacing EPS, EVA, and other foams. And yes, it’s technically edible (don’t worry, Evelio didn’t eat it on air). The Woamy team shares how they’ve already started replacing protective packaging in luxury products and where they see the most impact for brands that actually care about circular design.3 Things You’ll Learn:1. Why directional strength matters in foam packaging—and how it mimics wood.2. How Woamy achieves high performance with zero plastic and 90% air.3. What to consider when switching from EPS or EVA to recyclable cellulose foam.Mentions & Links:Woamy – https://woamy.com/FSC (Forest Stewardship Council) – https://fsc.org/IDP Direct – https://idpdirect.com/LinkedIn (Evelio Mattos) –   / eveliomattos  

Work with me:Let's design your packaging - https://www.linkedin.com/in/eveliomattos/Download the tools to design your own packaging - https://idpdirect.com/design-guides/Can you build a mass-market brand rooted in culture without crossing the line of appropriation?In this episode, Evelio Mattos talks with Victor Guardiola, co-founder and CEO of Bawi Agua Fresca, about launching a better-for-you beverage brand inspired by traditional Mexican flavors. We dive into the design decisions that made Bawi stand out on shelf, the importance of hiring diverse creative teams, and how to balance cultural authenticity with broad market appeal. This is a masterclass in packaging strategy, brand positioning, and knowing when consumer feedback trumps your gut—or when it doesn’t.

Struggling to make your packaging stand out on crowded shelves? In this episode of Packaging Unboxd, we break down two major redesigns by Chase Design Group—Dorot Gardens, a frozen garlic and herb brand that had to solve the problem of being invisible in the freezer aisle, and Tombstone Pizza, a refresh that modernized the brand while keeping its bold attitude intact. Learn how smart design choices, from color strategy to shelf visibility, can transform a product’s success. Whether you're a designer or launching a CPG brand, this episode delivers insights you can use today.

What will change in 2025 for packaging design and what concerns should brands have? Packaging design is evolving in 2025, listen to 20 top designers breakdown things you need to consider in 2025. Explore the evolving landscape of packaging in 2025 with industry experts like Al Gilbody, Anna Ison, and Dave from Print Design Academy. Discover themes including AI integration, cultural innovation in food packaging, and the rise of sustainable, regenerative, and soluble designs. Learn about the influence of Gen Z aesthetics from Fred Hart, evolving marketing strategies from Sarah Williams, and challenges posed by stringent regulations. With insights from voices like Guillermo Dufranc and Simon Forster, this episode delves into how packaging can transform consumer behavior and contribute positively to the environment, while maintaining creativity and brand storytelling. Designers in this episode include: Simon Forster of Robot-Food Anna Ison of Auros Design Gene Portnoy of Work & Company Al Gilbody of Slice Design Guillermo Dufranc of Tridimage Juan Campdera of Aktiva Fred Hart, Independent Design Consultant Chris Wilson of Stckmn Uwe Melichar of Touch Design Keenan Thompson of Phillip Morris International Matt Hanzly of Enlisted Design Dave Hopkins of Print Design Academy Sarah Williams of Beardwood & Co. Kirk Visola of Mind the Font Andy Kurts of Buttermilk Creative Chris Joscelyn of ButterflyCannon Lisa Cain of Surfit Westrock Vicki Strull, consultant and Evelio Mattos of IDP Direct

Discover the ultimate guide to Costco packaging design in this must-watch episode! Whether you're a designer, brand manager, or entrepreneur, we break down the secrets to designing packaging that meets Costco packaging requirements and sells. Learn how to navigate the unique challenges of club store packaging, from maximizing pallet efficiency to the "5-second, 5-foot rule" for grabbing customer attention. Find out why Costco demands more than just great design—it requires strategic thinking. We'll dive into the essentials of three-side shoppable pallets, the journey of earning a spot on the Costco floor, and how to innovate with sustainable materials like plastic-free packaging. Stay until the end to uncover the biggest missed opportunity in Costco packaging that could transform your approach to how to design packaging for club stores and beyond. Packed with actionable insights, this episode is your go-to resource for mastering Costco packaging requirements.