Designing the Packaging of Industrial Doors

Abstract

This Master’s Thesis was conducted in collaboration with ASSA ABLOY Entrance Systems, with the objective of improving the packaging system for the company’s industrial door panels. It is a common occurrence with the current packaging system that panels get damaged and need to be replaced. In addition, there are concerns regarding its sustainability, particularly in terms of the materials being used.

The defined problem was approached from the designer’s perspective, following the Double Diamond method with the integration of concepts from Ulrich & Eppinger’s product development process. The methodology allowed for a critical analysis of the task through different perspectives, which then resulted in a valuable collection of data
and input.

As a result, the proposed solution is an innovative concept that refines ASSA ABLOYs packaging system in a sustainable manner. In this final design, the use of plastic is significantly reduced and wood is introduced as the primary material. The design has its foundations on simplicity, with the focus being the protection of the most vulnerable parts of the panels. Furthermore, it is designed with the intention for its parts to be used more than once, with suggestion as to how this can be realised.

Popular Abstract

The task of designing a packaging system requires consideration of multiple factors, including the characteristics of the product being packed, the conditions it becomes subject to, and its overall impact on the environment, both directly and indirectly.

ASSA ABLOY has long faced challenges with the packaging of its industrial doors, particularly with the horizontal panels that comprise them. The current system does not offer sufficient protection to the panels and raises concerns about sustainability, especially regarding the materials used. This thesis tackles the task of creating an improved packaging solution for the company, while also studying packaging as an important part of its industrial activities.

Research, conducted through literature review and interviews, identified the requirements for the packaging of the door panels and highlighted key weaknesses in the current solution. The findings revealed that the materials currently in use are not well-suited to protect the panels under the conditions they endure before installation, often resulting in damages to the final products.

The design generated to resolve these problems is a comprehensive refinement of the current packaging solution, and does not require significant alterations in the company’s production flow in order to be implemented. The panels are packed vertically, a decision which is expected to minimise the damages occurring with the current solution. The concept’s foundations lie in simplicity and for that reason there is only a small number of materials being utilised, namely wood and recyclable plastic.

This project provides a valuable collection of information about the panels and their sustainable protection, while also proposing an innovative design. Beyond that however, it serves as an argument in favor of investing in the packaging of industrial doors, for the greater benefit of the company, as well as the environment.

• author: Habidis, Nireas Christos
• supervisor: Joze Tavcar
• organization: Innovation
• alternative title: Designing the Packaging of Industrial Doors: A project in Product and Packaging Development
• course: MMKM10 20242
• year: 2025
• type: H2 - Master's Degree (Two Years)
• subject: Technology and Engineering
• keywords: Packaging, Sustainability, Design, Product Development, Protection, Materials
• language: English
• id: 9183715
• date added to LUP: 2025-02-03 13:54:51
• date last changed: 2025-02-03 13:54:51