THE FMCG PACKAGING
CONSULTANT'S HANDBOOK

A Practical Guide to Packaging Development, Technical Specifications, Quality, Costing, Vendors, Operations & Cross-Functional Collaboration

A comprehensive practical reference for Packaging Consultants, Packaging Technologists, and FMCG professionals.

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Packaging Consultancy Goes Beyond Packaging Materials

Working as a packaging consultant in the FMCG industry involves much more than understanding bottles, cartons, flexible packaging or closures.

A packaging project can involve product development, material selection, technical specifications, artwork, testing, costing, suppliers, procurement, factory operations and cross-functional decision-making.

A consultant may need to communicate with:

R&D • Marketing • Procurement • Quality • Production • Supply Chain • Regulatory • Finance • Maintenance • Customer Service • Packaging Vendors

The ability to connect these areas is what makes packaging consultancy practical and effective.

The FMCG Packaging Consultant’s Handbook brings these areas together in one structured professional reference.
What Is This Handbook?

The FMCG Packaging Consultant’s Handbook is a practical reference created around the different technical, commercial and operational activities involved in FMCG packaging.

It brings together knowledge relating to:

  • Packaging materials and formats
  • Packaging technical specifications
  • Artwork and labelling
  • Printing and decoration
  • Packaging quality
  • Packaging testing
  • Packaging trials
  • Packaging benchmarking
  • Packaging costing
  • Packaging BOM
  • Procurement
  • Vendor selection
  • Vendor audits
  • Purchase orders
  • Inventory audits
  • Factory coordination
  • New product launches
  • Existing SKU operations
  • Innovative packaging
  • Interdepartmental discussions
  • Supplier and printer discussions
  • Packaging documentation

Rather than looking at these areas separately, the handbook presents them as interconnected parts of FMCG packaging consultancy.

WHY THIS HANDBOOK?
Because packaging decisions don’t happen in isolation.

A change in packaging material can affect:

Cost

Quality

Manufacturing

Supply Chain

Procurement

Regulatory Compliance

Consumer Experience

Sustainability

Brand Presentation

And ultimately, the success of the product.

A packaging consultant therefore needs to understand not only what the packaging is, but also how the packaging works within the wider FMCG business.

WHAT YOU’LL EXPLORE
1. PACKAGING MATERIALS & FORMATS

Build a practical understanding of common FMCG packaging formats and materials.

The handbook covers:

  • Plastic packaging
  • Glass
  • Aluminium
  • Tinplate
  • Paper & paperboard
  • Duplex cartons
  • CFB / corrugated packaging
  • Bottles
  • Jars
  • Flexible packaging
  • Tubes
  • Closures
  • Labels
  • Sustainable and alternative packaging materials
2. PACKAGING TECHNICAL SPECIFICATIONS

Packaging consultants need to be comfortable working with technical parameters.

The handbook covers areas including:

  • Density
  • Thickness
  • Tensile strength
  • Elongation
  • Barrier properties
  • Thermal properties
  • Chemical properties
  • Surface finish
  • Printing compatibility
  • Environmental considerations
  • Regulatory compliance
  • Supplier information
  • Cost information
3. PACKAGING ARTWORK & LABELLING

Packaging artwork connects technical packaging requirements with brand and regulatory requirements.

Explore practical considerations around:

  • Artwork requirements
  • Artwork parameters
  • Label materials
  • Labelling information
  • Printing requirements
  • Graphics and design
  • Regulatory information
  • Artwork review
  • Print quality
  • Legibility
4. PRINTING & PACKAGING DECORATION

Understand the printing and decoration considerations associated with FMCG packaging.

Topics include:

  • Flexographic printing
  • Offset printing
  • Digital printing
  • Screen printing
  • Gravure printing
  • Ink adhesion
  • Print quality
  • Special effects
  • Special finishes
5. PACKAGING QUALITY, TESTING & VALIDATION

Packaging must perform through production, transportation, storage and consumer use.

The handbook covers practical packaging testing and quality considerations including:

  • Drop testing
  • Compression testing
  • Leak testing
  • Burst testing
  • Barrier testing
  • Moisture barrier
  • Oxygen transmission
  • Print density
  • Rub resistance
  • Temperature and humidity
  • Light exposure
  • Regulatory testing
  • Shelf-life testing
  • Accelerated ageing
6. PACKAGING TRIALS

Move from packaging concept towards practical validation.

Explore:

  • Trial objectives
  • Trial types
  • Trial setup
  • Sample size
  • Packaging design
  • Packaging materials
  • Packaging format
  • Dimensions
  • Closures
  • Labelling
  • Testing protocols
  • Data collection
  • Packaging performance
  • User experience
  • Shelf-life stability
  • Transit and handling
  • Results
  • Recommendations
  • Follow-up actions
7. PACKAGING BENCHMARKING

Packaging consultants may need to evaluate existing market solutions before recommending a packaging direction.

The handbook covers:

  • Competitor packaging
  • Packaging materials
  • Packaging formats
  • Size and capacity
  • Pricing
  • Design
  • Functionality
  • Environmental impact
  • Regulatory requirements
  • Testing
  • Supplier evaluation
  • Timelines
  • KPIs
8. PACKAGING COSTING

Technical decisions also have commercial consequences.

Understand packaging cost considerations including:

  • Material cost
  • Component cost
  • Printing cost
  • Labour
  • Transportation
  • Machinery requirements
  • Cost per unit
  • Total packaging cost
  • MOQ
  • Cost optimization
9. PACKAGING BILL OF MATERIALS

A packaging BOM brings the components of a packaging system together.

The handbook covers:

  • Primary packaging
  • Secondary packaging
  • Labels
  • Inserts
  • Closures
  • Seals
  • Protective packaging
  • Product holders
  • Documentation
  • Accessories
  • Quantity and usage
  • Supplier information
  • Component costs
10. PACKAGING PROCUREMENT

Packaging development eventually connects with procurement and commercial implementation.

Topics include:

  • Procurement requirements
  • Supplier identification
  • Supplier evaluation
  • Specifications
  • Pricing
  • MOQ
  • Lead times
  • Commercial terms
  • Contracts
  • Procurement coordination
11. PACKAGING VENDOR MANAGEMENT

A packaging consultant frequently works directly with packaging suppliers.

The handbook covers vendor evaluation based on:

  • Quality
  • Reliability
  • Cost
  • Lead time
  • Flexibility
  • Sustainability
  • Supply-chain capability
  • Technical expertise
  • Production capacity
  • Communication
  • Reputation
  • Financial stability
  • Regulatory compliance
  • Innovation
12. PACKAGING VENDOR AUDITS

Develop a structured approach to evaluating packaging suppliers.

Topics include:

  • Vendor information
  • Audit scope
  • Audit criteria
  • Audit team
  • Pre-audit preparation
  • On-site audit
  • Data collection
  • Quality management systems
  • Product quality
  • Regulatory compliance
  • Delivery performance
  • Customer service
  • Strengths and weaknesses
  • Corrective actions
  • Recommendations
  • Audit reporting
  • Follow-up
13. PACKAGING PURCHASE ORDERS

Understand the information that may need to be captured in packaging purchase orders.

Including:

  • Supplier information
  • Product details
  • SKU
  • Packaging type
  • Packaging specifications
  • Quantity
  • Dimensions
  • Colour and finish
  • Delivery
  • Shipping
  • Payment terms
  • Pricing
  • Quality requirements
  • Special instructions
  • Approval
  • Terms and conditions
  • Attachments
14. PACKAGING INVENTORY & AUDIT

Packaging operations continue after development and procurement.

The handbook covers:

  • Inventory locations
  • Inventory items
  • Physical inventory
  • Documentation review
  • Sampling
  • Inventory accuracy
  • Reconciliation
  • Inventory discrepancies
  • Root-cause analysis
  • Corrective actions
  • Process improvements
  • Training
  • Follow-up
15. INNOVATIVE PACKAGING DEVELOPMENT

Packaging consultants may also be involved in developing differentiated packaging solutions.

Explore:

  • Product characteristics
  • Target market
  • Branding objectives
  • Shelf appeal
  • Functionality
  • Sustainability
  • Packaging compatibility
  • Innovative concepts
  • Vendor brainstorming
  • Creative solutions
  • Product differentiation
  • Consumer engagement
THE CROSS-FUNCTIONAL SIDE OF PACKAGING CONSULTANCY
Packaging doesn’t belong to one department.

One of the important areas covered in this handbook is interdepartmental packaging discussion.

A Packaging Consultant may need to understand the requirements and questions coming from different FMCG functions.

R&D / PRODUCT DEVELOPMENT

Packaging discussions can involve:

  • Product characteristics
  • Product–packaging compatibility
  • Packaging requirements
  • Material selection
  • Packaging trials
  • Technical challenges
MARKETING

Packaging discussions can involve:

  • Brand positioning
  • Packaging design
  • Consumer appeal
  • Shelf impact
  • Graphics
  • Packaging communication
  • Innovation
PROCUREMENT

Packaging discussions can involve:

  • Supplier selection
  • Pricing
  • MOQ
  • Lead time
  • Negotiation
  • Commercial terms
  • Supplier performance
  • Cost optimization
QUALITY ASSURANCE

Packaging discussions can involve:

  • Specifications
  • Quality standards
  • Testing
  • Acceptance criteria
  • Packaging defects
  • Quality complaints
  • Corrective actions
  • Compliance
PRODUCTION & MANUFACTURING

Packaging discussions can involve:

  • Packaging-line compatibility
  • Filling and packing
  • Machinery
  • Production trials
  • Process issues
  • Packaging performance
  • Troubleshooting
SUPPLY CHAIN

Packaging discussions can involve:

  • Inventory
  • Warehousing
  • Transportation
  • Logistics
  • Stock availability
  • Packaging planning
  • Supplier coordination
REGULATORY

Packaging discussions can involve:

  • Regulatory requirements
  • Labelling
  • Compliance
  • Safety requirements
  • Documentation
  • Certifications
FINANCE

Packaging discussions can involve:

  • Packaging cost
  • Cost breakup
  • Budgets
  • Cost optimization
  • Commercial evaluation
  • Financial impact
MAINTENANCE

Packaging discussions can involve:

  • Packaging machinery
  • Equipment maintenance
  • Technical issues
  • Spare parts
  • Preventive maintenance
  • Predictive maintenance
  • Emergency response
CUSTOMER SERVICE

Packaging discussions can involve:

  • Consumer feedback
  • Packaging complaints
  • Packaging-related issues
  • Complaint analysis
  • Corrective actions
  • Consumer experience
WORKING WITH EXTERNAL PACKAGING STAKEHOLDERS

The consultant’s role can also extend beyond internal departments.

The handbook covers practical discussions with:

Packaging Vendors

  • Existing SKUs
  • New SKUs
  • Material specifications
  • Quality requirements
  • Samples
  • Trials
  • Pricing
  • Cost optimization
  • Innovation

Printers & Packaging Converters

  • Printing methods
  • Artwork
  • Print quality
  • Special effects
  • Finishes
  • Technical requirements
  • Production considerations

Suppliers

  • Capability
  • Material options
  • Lead times
  • Commercial terms
  • Quality
  • Innovation
  • Supply continuity
PACKAGING OPERATIONS & FACTORY COORDINATION

Packaging consultancy does not necessarily end once a packaging format has been approved.

The handbook also covers the operational side of packaging, including:

  • Equipment maintenance
  • Process optimization
  • Training
  • Quality standards
  • Quality control
  • Root-cause analysis
  • Inventory management
  • Supplier management
  • Transportation
  • Procurement
  • Contract management
  • Risk management
  • Factory coordination
  • Emergency response
NEW PRODUCT LAUNCH

Packaging plays an important role when launching a new FMCG product.

The handbook brings together the packaging-related discussions required across:

R&D → Marketing → Procurement → Quality → Production → Supply Chain → Regulatory → Finance → Vendors

The objective is to help ensure that packaging requirements are considered before the product moves into commercial production.

EXISTING SKU MANAGEMENT

Packaging consultants may also support products that are already in the market.

The handbook covers discussions around:

  • Existing packaging
  • Quality issues
  • Supplier performance
  • Cost
  • Inventory
  • Production
  • Packaging improvements
  • Process optimization
  • Consumer feedback
  • Corrective actions
  • Continuous improvement
PRACTICAL CONSULTANCY TOOLS & FRAMEWORKS

The handbook brings together practical parameter-based resources for areas such as:

  • Packaging specifications
  • Packaging BOM
  • Packaging trials
  • Vendor selection
  • Vendor audits
  • Purchase orders
  • Inventory audits
  • Packaging benchmarking
  • Packaging testing
  • Packaging documentation

These resources can serve as working references when structuring packaging projects and discussions.

TABLE OF CONTENTS
PART I — THE FMCG PACKAGING CONSULTANT
  1. Understanding FMCG Packaging Consultancy
  2. Packaging in the New Product Development Process
PART II — FMCG PACKAGING MATERIALS & FORMATS
  1. Packaging Materials
  2. Duplex Carton Packaging
  3. CFB & Corrugated Packaging
  4. Bottle Packaging
  5. Jar Packaging
  6. Flexible Packaging
  7. Tube Packaging
  8. Closures
PART III — PACKAGING DEVELOPMENT & TECHNICAL MANAGEMENT
  1. Packaging Technical Specifications
  2. Packaging Artwork & Labelling
  3. Printing & Packaging Decoration
  4. Packaging Bill of Materials
PART IV — PACKAGING QUALITY, TESTING & TRIALS
  1. Packaging Quality Management
  2. Packaging Testing
  3. Packaging Trials
  4. Packaging Benchmarking
PART V — PACKAGING COSTING, PROCUREMENT & SUPPLY CHAIN
  1. Packaging Cost Breakup
  2. Packaging Procurement
  3. Packaging Purchase Orders
  4. Packaging Inventory Management & Audit
PART VI — PACKAGING VENDORS & SUPPLIER MANAGEMENT
  1. Packaging Vendor Selection
  2. Packaging Vendor Audit
  3. Working With Packaging Vendors
  4. Innovative Packaging Development
PART VII — CROSS-FUNCTIONAL FMCG PACKAGING CONSULTANCY
  1. Working With R&D / Product Development
  2. Working With Marketing
  3. Working With Procurement
  4. Working With Quality Assurance
  5. Working With Production & Manufacturing
  6. Working With Supply Chain
  7. Working With Regulatory Affairs
  8. Working With Finance
  9. Working With Maintenance
  10. Working With Customer Service
PART VIII — PACKAGING OPERATIONS & FACTORY COORDINATION
  1. Maintaining Existing Packaging Operations
  2. Packaging Technologist–Factory Discussions
  3. Packaging Discussions During New Product Launch
PART IX — PRACTICAL PACKAGING CONSULTANCY TOOLS
  1. Packaging Parameter Sheets
  2. Packaging Documentation & Records
  3. Packaging Consultant’s Working Framework
APPENDICES
  • Packaging Material Reference
  • Packaging Technical Parameters
  • Packaging Testing Reference
  • Packaging Vendor Evaluation Parameters
  • Packaging Audit Parameters
  • Packaging BOM Reference
  • Packaging Trial Parameters
  • Packaging Purchase Order Parameters
  • Packaging Inventory Audit Parameters
  • Packaging Benchmarking Parameters
WHO IS THIS HANDBOOK FOR?
Packaging Consultants

For professionals supporting FMCG clients across packaging development, suppliers, technical evaluation and implementation.

Packaging Technologists

For technical packaging development, specifications, testing, trials and quality.

FMCG Founders & Startups

For understanding the packaging activities involved in developing and commercializing FMCG products.

Procurement Professionals

For understanding packaging specifications, suppliers, costing and purchasing requirements.

Quality Professionals

For packaging quality, testing, specifications, trials and audits.

FMCG Operations & Supply Chain Professionals

For understanding the operational and supply-chain side of packaging.

Students & Early-Career Professionals

For building practical exposure to FMCG packaging and its cross-functional role.

MORE THAN A PACKAGING MATERIAL GUIDE

This handbook is designed around a simple reality:

A packaging consultant needs to understand both the packaging and the business environment in which that packaging operates.

From materials and specifications to testing, costing and suppliers.

From vendor discussions to factory coordination.

From R&D and Marketing to Procurement, Quality and Supply Chain.

From new product launches to existing SKU management.

The handbook brings these interconnected areas together in one practical resource.

BUILD A MORE STRUCTURED APPROACH TO FMCG PACKAGING CONSULTANCY

Whether you are starting a packaging consultancy project, supporting an FMCG founder, working with a packaging supplier or managing packaging within an established FMCG organization, having a structured reference can help bring clarity to the work.

Understand the Packaging.
Understand the Process.
Understand the Stakeholders.
Structure the Work.
GET THE FMCG PACKAGING CONSULTANT’S HANDBOOK
A Practical Guide to Packaging Development, Technical Specifications, Quality, Costing, Vendors, Operations & Cross-Functional Collaboration

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