Welcome to Packaging Clinic & Research Institute!

“A deep-dive diagnostic of your packaging ecosystem”

A Packaging Audit is a structured and systematic review of all packaging-related activities in an organization—from material sourcing to final product dispatch. It helps identify areas of improvement, cost-saving opportunities, and compliance gaps while promoting safety, sustainability, and efficiency.

Objectives of a Packaging Audit

Evaluate Packaging Efficiency – Assess if the packaging system is performing optimally in terms of cost, performance, and process.
Ensure Compliance – Verify adherence to applicable legal, safety, and regulatory standards (like FSSAI, BIS, ISO, PWM Rules).
Detect Deficiencies – Identify weaknesses, packaging failures, over-packaging, and under-packaging.
Recommend Improvements – Suggest actionable changes for material savings, sustainable alternatives, and improved pack performance.
Support Decision-Making – Provide data-backed insights for management to make strategic packaging decisions.

Scope of the Packaging Audit

1. Material Assessment

Type, specification, and source of packaging materials used.
Suitability for product protection and shelf life.
Opportunities for substitution (bio-based, recycled, recyclable materials).
Print quality and compatibility with packaging machines.

2. Design and Structure Review

Ergonomics, strength, and stackability.
Aesthetic appeal and shelf presence.
Primary, secondary, tertiary packaging consistency.
Space utilization and unit load optimization.

3. Packaging Line & Operations

Line layout and efficiency.
Manual vs. automated operations.
Waste generation and rework percentage.
Storage, handling, and transportation issues.

4. Compliance & Documentation

Labeling as per regulatory requirements (e.g., FSSAI, Legal Metrology, GHS).
Material safety data sheets (MSDS) and specifications.
Plastic Waste Management (PWM) and Extended Producer Responsibility (EPR) compliance.
Use of food-contact safe inks, adhesives, and laminates.

5. Cost Analysis

Per-unit packaging cost breakup.
Freight and logistics implications of current packaging.
Over-packaging or material inefficiencies.
ROI analysis for proposed packaging changes.

6. Sustainability Footprint

Use of recyclable, reusable, or compostable materials.
Carbon footprint of packaging.
End-of-life disposal and recyclability analysis.

Tools and Techniques Used

Visual inspection and sampling.
Drop, compression, and transit testing (if part of the audit scope).
Interviews with line supervisors, QC teams, and procurement heads.
Packaging cost benchmarking.
Packaging waste audit (type, volume, recyclability).

Deliverables of a Packaging Audit

Packaging Audit Report with:
- Observations and finding
- Non-conformance or improvement areas
- Root cause analysis of failures (if applicable)
- Photographic evidence
Recommendations & Action Plan
Packaging Compliance Checklist
Sustainable Packaging Roadmap (if applicable)
Training Need Identification for internal teams

Who Needs a Packaging Audit?

Food Processing Units
Pharmaceutical Manufacturers
SMEs and Exporters
E-commerce Brands
Warehousing & Distribution Hubs
CSR and NGOs working on packaging hygiene/safety

Frequency

Packaging audits may be:

One-time (during launches, certifications, or for troubleshooting)
Periodic (annual, half-yearly)
Continuous (for large setups with in-house PCRI presence)

Why PCRI for Packaging Audit?

Backed by decades of packaging expertise.
Cross-sector knowledge (food, pharma, industrial, FMCG).
Strong focus on compliance and sustainability.
Access to a network of testing labs for material validation.
Customizable approach based on client’s budget and scale.

Packaging Clinic & Research Institute

ISO:9001:2015 Certified Institute