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This paper seeks to analyze the concept of packaging re-design with the main purpose to better exploit the utilized space within a secondary packaging, pallet and/or to make better use of transport, respectively. In addition, it investigates and discusses the importance of space exploitation in relation to environmental benefits, the industry and the community in general.

The research is based on a specific case study, in which two different options of a bottle with the same capacity are investigated in terms of: shape and space utilization. The investigation includes a detailed numerical comparison between the bottles, in order to show the strengths and weaknesses of each option.

The analysis provides evidence that any shape improvements could result into benefits such as: reduce waste, increase space utilization and increase the number of transported products per load. This in turn could reduce the energy and CO₂ emissions required per unit of product carried or stored. The analysis shows that a better utilization of the space could further offer significant economic benefits for the company with respect to transportation and warehousing.

However, the proposed packaging design solutions are proposed with the guarantee that the protection of the product is ensured, the logistics activities are facilitated as expected, the needs of the user are fully covered and the cost is maintained low. This solution, therefore, addresses the economic, social and environmental aspect of packaging.

This paper fulfills an identified need to study the relation between the packaging redesign concept and the various environmental and economic benefits for the industry and the participants of the supply chain, while maintaining the needs of the user. This works contributes to other more recent studies that are concerned with packaging design innovation that respond to key environmental concerns.