A product reaches the customer in more than one packaging item. It may have a bottle or tray, a carton, a shrink wrap, a grouped carton, dividers and pallet wrap. If all these elements are entered into a single record, it is difficult to establish which level is being assessed, how much material is attributable to the unit and who supplies a given component.
The level results from the function in the configuration
Sales packaging is linked to the sales unit intended for the end user. Grouped packaging groups a specified number of units, while transport packaging facilitates handling and transport. These terms should not be assigned merely on the basis of the name of the element, because the same carton may perform a different function in different sales models.
The data must preserve the relationship: how many lower-level packaging items a higher level contains, which components belong to it and whether the item remains with the product until the point of sale. The model should describe a specific distribution scenario.
Sales packaging
At sales level, it is worth recording all elements passed to the consumer together with the product: container, closure, label, box, insert and protective materials. Each component may have its own material, mass and data source.
A product variant may change the configuration. A promotional set, a sample or a multipack sale does not always use the same packaging. The link to the SKU and market should therefore be explicit, and the version validity date should make it possible to reconstruct the historical state.
Grouped packaging
The grouped level combines several units and may be removed without affecting the product's characteristics. Information is needed on the number of units, components, mass and method of separation. If grouped packaging reaches the consumer in multipack sales, the actual offer model must be taken into account.
The grouped mass should not be divided by a default number of items without recording the conversion factor. A change in the number of units in a carton affects the result attributable to the product. Every conversion rule should have a version and scope.
Transport packaging
Transport packaging is used for handling and transporting multiple units or grouped packaging items. It may include a carton, film, tapes, corner boards, layer pads and pallet elements, taking into account the relevant exclusions and definitions. The configuration depends on the route, method of fulfilment and quantity.
Logistics data are sometimes stored outside the product catalogue. For PPWR, however, a controlled link to the configuration is needed. It is worth distinguishing the shipping standard from actual consumption and preserving the source of the factors used for conversions.
Relationships between levels
The clearest model resembles a tree. A node describes a level, and beneath it are components or lower-level configurations together with quantity. This makes it possible to calculate mass for the sales unit, carton and shipment without manually copying the same values.
The tree should be versioned as a whole. If the number of items in a carton changes, the new revision must not change historical results. Products sold earlier remain linked to the configuration in force at that time.
Unusual cases requiring a decision
Reusable packaging, food service packaging, sets, elements integral to the product and packaging used in several channels may require additional analysis. The system should make it possible to describe the exception and attach the basis, instead of forcing an unsuitable category.
If a company is not certain of the classification, the record may remain in a status pending verification. An incomplete decision must be visible in the work plan and block the final document where it matters.
Configuration checklist
- determine the sales unit,
- record all levels used in the actual channel,
- add components and their quantities,
- assign materials, masses and suppliers,
- preserve conversion factors between levels,
- indicate markets and channels,
- describe exceptions and assumptions,
- approve the version with a validity date,
- link documents and calculations,
- do not overwrite the historical configuration.
Why structure matters
Without levels, data may look complete even though it is not clear what they relate to. An organised configuration makes it possible to direct questions to the right suppliers and prepare reliable calculations.
GPSR / PPWR stores a snapshot of the packaging, components and sources. Classification still requires a decision by the undertaking based on actual use and current regulations.
Control after a change of sales channel
The same product unit may use different packaging in a physical shop, courier shipment and pallet delivery. Adding a channel should therefore trigger a review of the entire tree, not merely the addition of the carrier's name.
It is worth recording a reference scenario and separate logistics variants. This makes it possible to compare masses, identify common elements and assign responsibility for transport data. If the conversion factor depends on the fill rate of the carton or pallet, the assumption must be visible in the result.