Ergonomic packaging applies to the complex human factors of packaging design. Ergonomics means well-designed, usable, user-friendly, safe and comfortable to use. For packaging design-tech, ergonomics is a topic of primary concern. 

PopPack begins its design process with the consumer-user in mind.  Ours is a design-first approach.

At PopPack, we strive to ensure that consumers benefit from high quality and safe packaging. We are attuned to providing packaging for social equity, designed for all ages and abilities.

For more than a decade, we studied how people of all ages open packages.  We have developed, designed, engineered and introduced a better way of making packages easy to open, simple to use, and reclose.  Additionally, our EasyPop^® has no-spill features and portion controls.  The EasyPop^® design combines hundreds of complex human factors into one solution.

What we found is that many children could not open packages on their own, without the assistance of adults.  Additionally, we studied the challenges of lost hand strength for the senior population, for the disabled and package use difficulties for the sight impaired.

Most seniors over age 75 who we interviewed had a “great degree of frustration” opening packages.  Many seniors who we studied lived alone.  Some seniors recounted their own personal stories of purchasing food and other goods at the local store, carrying products home, and then throwing them away because they could not open the packages without help.

Statistics show that by 2050, the population of consumers over age 50 will grow by 1.2 billion. (Foreign Policy)

Consumers of all ages continue to struggle to open packages, yet they still can’t get to the product without biting the package or using a knife or scissors. Typically, consumers use sharp tools to open tightly sealed packages. Accidental cuts, bruises, gashes and other injuries are a result of packages that are too difficult to open. Packages are torn and ripped, products are spilled, and food is wasted.  Once the package is torn, specialty reclosing devices such as zippers and sliders become unworkable.  Without ergonomic packaging, the consumer is frustrated and inconvenienced, resulting in a loss of brand loyalty.

Furthermore, we researched hospital emergency room injuries caused by packaging. Each year, across the world, hundreds of thousands of people visit hospital emergency rooms due to injuries from opening packages. Most of these injuries, involve hand strains and damage to teeth. Other common injuries are caused by the improper use of knives and scissors.

More than 50 million people in the USA suffer from arthritis.  This equates to over 500 million people worldwide who do not have the hand strength required to open flexible packages!

Specifically, for a hand arthritis afflicted patient, the most common arthritis is located right at the “Basel Joint” where the greatest strength is needed.  Therefore, opening a package which requires tearing is often next to impossible. The “Basel Joint” of the thumb is put under continuous strain when opening most flexible packages.

The most difficult part of the opening process is starting the tear of the package.  Once started, the consumer must then sustain a constant, continuous force over time in order to complete the tear-open process. Holding the thumb and forefinger of the hand in position to “pinch hold” becomes more challenging the longer time it takes to complete the tear. The joint strain and pinch pressure are significant obstacles for seniors and children who typically have weakness in their hands.

The American Society for Surgery of the Hand (ASSH) claims, “The most common symptom of thumb basal joint arthritis is a deep, aching pain at the base of the thumb.  The pain is often worsened with activities that involve pinch, including opening jars…” The large joints in the hand at the base of each finger are known as the metacarpophalangeal joints.  They act as complex hinge joints and are important for both power grip and pinch activities.”

PopPack is studying the use of packaging for food, beverages, consumer goods, personal care, health care and other products where environments may be wet, slippery, or require a “one-handed opening” process.  PopPack is also working on packaging solutions that are designed to minimize contamination so that customers do not need to risk touching the product when consumed.  Additionally, the feel, shape, size and touch of the package are all ergonomic factors that are considered with our design-tech process.

For the on-the-go lifestyles, PopPack’s EasyPop^® design allows consumers to ‘pop’ the air bubble in the package using only one hand.  This is a convenient feature for consumers especially when they need to open a package while using a mobile device, driving a car or bicycle, preparing food or holding a small child.  Single-handed opening is a valuable ergonomic feature seldom found in packaging design.  Light-weighting the packaging with minimal packaging materials, also provides an added convenience.

The EasyPop^® Air Powered Package^™ incorporates an air bubble within the packages’ seals.  This ergonomic packaging feature allows customers to quickly, easily and safely open many types of packages.

Our ultimate goal is to consider all human factors concurrently so that packaging is easy and reliable to safely open for all ages and abilities – everyday, everywhere and every time.

We thank our affiliates and dedicated colleagues for their assistance and support with our Research and Development for this initiative who have worked in collaboration with PopPack LLC and our affiliates.

University of California, San Francisco, Department of Hand Orthopedics, Dr. Edward Diao (See video)
Lund University, Sweden
Flextrus, Sweden
Food Valley, The Netherlands
Michigan State University (School of Packaging)
Arthritis Foundation, USA
Arla Foods (Brand Owner)