Custom Solutions

Tailored packaging solutions designed around your unique operational requirements and business goals. From consultation to ongoing management, we build programs that deliver measurable ROI.

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What We Offer

Every business is unique, and so are its packaging needs. A solution that works perfectly for a food processor will not work for an e-commerce fulfillment center, and what a chemical distributor needs is entirely different from what a produce farm requires. That is why PackMesa invests the time to understand your specific operation before recommending anything.

Our custom solutions team works closely with you to develop a packaging program that addresses your specific challenges — whether that is reducing costs, improving reliability, meeting compliance requirements, reducing waste, or all of the above. We combine products, services, logistics, and expertise into a single integrated program managed by a dedicated account manager who knows your business inside and out.

The result? On average, our custom solution clients see a 35% reduction in total packaging costs within the first year, with many achieving payback on the program within 60 days. More importantly, they gain a packaging partner who proactively manages and optimizes their program over time — freeing them to focus on what they do best.

Core Custom Solution Components

Mix and match these components to build the ideal program for your business. Most clients use a combination of three or more.

Custom Sizing & Specifications

Need non-standard sizes or specific material specifications? We source and process materials to your exact requirements — from custom box dimensions and wall thicknesses to specialized liner materials and printed branding.

Custom box dimensions (any size)
Specific wall thicknesses & flute types
Special material requirements
Printed/branded options
Color coding systems
Custom liner specifications

Specialized Processing

Our facility can process materials to meet unique requirements. From precision cutting and pre-assembly to cleaning, sanitizing, and reconditioning, we handle the preparation work so materials arrive ready to use.

Custom cutting & trimming
Pre-assembly of packaging kits
Cleaning & sanitizing to spec
Reconditioning & repair
Sorting & grading to custom standards
Quality testing & certification

Inventory Management

Let us manage your packaging inventory so you always have what you need without tying up warehouse space or management time. We stock, track, reorder, and deliver on your schedule.

Dedicated off-site inventory
Automated reorder triggers
Just-in-time delivery
Usage tracking & reporting
Safety stock management
Multi-location support

Consultation Services

Our packaging experts evaluate your operation and recommend optimal solutions for efficiency, cost savings, and sustainability. From initial audits to ongoing optimization, we bring decades of expertise.

Comprehensive packaging audits
Cost optimization studies
Sustainability planning
Material specification engineering
Supply chain review
Vendor consolidation strategy

From Consultation to Delivery

Our proven six-step process ensures every custom solution is thoroughly designed, carefully implemented, and continuously optimized.

Discovery Consultation

We start with a thorough conversation about your packaging challenges, operational requirements, budget constraints, and goals. This may include an on-site visit to your facility to observe your packaging workflow firsthand. There is no cost or obligation for this initial consultation.

1-3 days

Needs Assessment & Audit

Our team conducts a detailed assessment of your current packaging usage, costs, waste, and pain points. We analyze your material specifications, volume patterns, storage constraints, compliance requirements, and supplier relationships. This is where we identify the biggest opportunities for improvement.

3-5 days

Solution Design

Based on the assessment, we design a custom solution addressing your specific needs. This may include product recommendations, custom specifications, inventory management protocols, delivery schedules, recycling programs, and projected cost savings. We present the complete plan for your review and feedback.

5-7 days

Proposal & Approval

You receive a formal proposal with detailed specifications, pricing, implementation timeline, and projected ROI. We walk through every element to ensure alignment and answer all questions. Revisions are made based on your feedback until the solution is exactly right.

3-5 days

Implementation

Our team handles all implementation logistics — sourcing materials, configuring inventory systems, establishing delivery routes, training your team on new procedures, and transitioning from your existing suppliers. We manage the entire cutover process to ensure zero disruption to your operations.

1-4 weeks

Ongoing Management & Optimization

After launch, your dedicated account manager monitors performance, handles day-to-day operations, and continuously looks for optimization opportunities. We provide regular reporting on usage, costs, savings, and sustainability metrics. Quarterly reviews ensure the program evolves with your business.

Ongoing

Customization Options

A comprehensive menu of customization capabilities across product, processing, and program levels.

Product Customization

Option	Description	Available For
Custom Box Dimensions	Non-standard sizes manufactured to your exact specifications	All product types
Wall Thickness / Flute Type	Single, double, or triple wall based on load requirements	Gaylord boxes, corrugated
Custom Printing / Branding	Your logo, handling instructions, or barcodes printed on packaging	Gaylords, bags, drums
Liner Selection	PE, foil, food-grade, anti-static, or vapor barrier liners	Gaylords, bulk bags, drums
Color Coding	Color-coded packaging for product differentiation or quality sorting	All product types

Processing Services

Option	Description	Available For
Custom Cutting & Trimming	Materials cut to specific dimensions for your application	Corrugated, foam, wood
Assembly Services	Pre-assembled packaging kits delivered ready to use	Box + liner + pallet combos
Cleaning & Sanitizing	Pressure wash, sanitize, and certify used containers	IBC totes, drums, gaylords
Reconditioning	Full reconditioning including repairs, valve replacement, testing	IBC totes, drums
Sorting & Grading	Materials sorted and graded to your custom specifications	All used products

Program Services

Option	Description	Available For
Inventory Management	We stock, track, and deliver your packaging on demand	All account types
Just-in-Time Delivery	Materials delivered precisely when needed — no early, no late	Recurring accounts
Reverse Logistics	We collect, sort, and process your used packaging after use	All account types
Closed-Loop Programs	Packaging circles back through reconditioning for reuse	Totes, drums, pallets
Vendor Consolidation	Replace multiple suppliers with a single PackMesa program	All account types

Full Custom Solution (All Services Combined)

Payback: 1-3 months

Investment Required

Consultation and program setup (typically $0 — absorbed into service pricing)

Expected Savings

30-50% reduction in total packaging lifecycle costs

Example

A food processor spending $500,000/year on packaging procurement, disposal, and logistics implements a full PackMesa program and reduces total cost to $250,000-$350,000/year.

Case Studies

See how PackMesa custom solutions are delivering real results for Arizona businesses.

Automotive Manufacturing

Automotive Parts Manufacturer Redesigns Packaging Flow

Challenge

A Chandler-based automotive parts manufacturer was using one-size-fits-all gaylord boxes for shipping components of vastly different sizes and weights. Small parts rattled around in oversized containers, causing damage. Heavy parts exceeded weight ratings on standard boxes, leading to failures during transit. They were also managing inventory manually, resulting in frequent stockouts that halted their shipping line.

Solution

PackMesa designed a three-tier packaging system: small gaylords with custom inserts for precision components, standard gaylords with reinforced bottoms for mid-weight parts, and heavy-duty triple-wall gaylords for their heaviest assemblies. We also implemented a just-in-time inventory management program that automatically triggers reorders based on consumption data, maintaining a 2-week safety stock at their facility.

Results

Transit damage reduced by 78% (from 4.2% to 0.9% damage rate)
Packaging costs reduced by 31% through right-sizing
Zero stockouts in first 18 months of inventory program
Shipping line downtime eliminated — previously averaged 6 hours per month
Annual savings of $142,000 in packaging, damage claims, and labor

Food Processing

Food Processor Builds Compliant Closed-Loop System

Challenge

A large food processing operation in Mesa needed food-grade packaging for shipping bulk ingredients to production facilities. They were buying new IBC totes and gaylords for every shipment, then disposing of them after single use. Compliance requirements meant they could not use random used containers — every unit needed documented chain of custody and sanitization records.

Solution

PackMesa built a closed-loop packaging program using reconditioned IBC totes and food-grade lined gaylords. Each unit is tracked with a unique ID, sanitized to food-grade standards at our facility after each use, inspected, and returned to the customer's rotation pool. Full documentation is maintained for regulatory compliance, including sanitization certificates and chain of custody logs.

Results

Packaging spend reduced by 57% ($234,000 annual savings)
Full FDA and food safety compliance maintained with documentation
Container lifecycle extended from 1 use to 8-12 uses per unit
Waste generation reduced by 85% — near-zero disposal
Dedicated account manager handles all compliance documentation

E-Commerce / Fulfillment

E-Commerce Company Scales Packaging for 300% Growth

Challenge

A rapidly growing e-commerce company in the Phoenix area was tripling their order volume over 18 months. Their existing packaging supplier could not keep up with demand, leading to missed ship dates. They were also outgrowing their warehouse space and could not dedicate more floor area to packaging inventory.

Solution

PackMesa designed a scalable packaging supply program with off-site inventory management. We maintain a dedicated inventory of their packaging materials at our Mesa facility, with daily scheduled deliveries based on their pick-and-pack schedule. Volume scales up and down automatically based on order forecasts they share weekly. We also consolidated their four previous suppliers into a single program.

Results

Zero missed ship dates due to packaging shortages since program launch
Freed up 3,200 sq ft of warehouse space (previously used for packaging storage)
Packaging cost per order reduced by 28% through better sourcing and right-sizing
Supplier management simplified from 4 vendors to 1
Scaled smoothly from 2,000 to 8,000 orders per week over 18 months

Chemical Distribution

Chemical Distributor Implements Tote Reconditioning Program

Challenge

A chemical distribution company was purchasing new IBC totes at $320 each, using them for a single customer shipment, then either disposing of them or letting customers keep them. With 1,200 totes per year, this represented a massive and growing cost. Regulatory requirements meant they needed full traceability on every container.

Solution

PackMesa implemented a comprehensive tote reconditioning program. We collect used totes from the distributor's customers, inspect and pressure-test each unit, replace gaskets and valves as needed, clean according to the appropriate protocol for the previous contents, and return reconditioned totes to inventory. Each tote's full history is tracked in our system.

Results

Tote costs reduced from $384,000/year to $127,000/year (67% savings)
Average tote goes through 6 reconditioning cycles before retirement
Full chain of custody documentation maintained for every unit
Customer return rate improved from 35% to 82% with incentive program
Environmental benefit: 900+ totes diverted from landfill annually

Industry-Specific Solutions

We have deep experience in these industries and have developed specialized solutions for each.

Manufacturing

Production-line packaging programs that keep your lines running without interruption. Custom specifications for your product requirements, just-in-time delivery, and scrap packaging recycling.

Line-side delivery programs
Custom-spec packaging
Scrap and waste recycling
Returnable container programs
Seasonal surge capacity

Food & Beverage

FDA-compliant packaging programs with full traceability, sanitization protocols, and documentation. Closed-loop systems that minimize waste while maintaining food safety standards.

Food-grade container programs
Sanitization & certification
Chain of custody tracking
Closed-loop reconditioning
Compliance documentation

Agriculture & Produce

Harvest-ready packaging available on demand with seasonal surge capacity. Field delivery, produce-grade containers, and flexible programs that scale with your growing season.

Seasonal scaling programs
Field-side delivery
Produce-grade containers
Post-harvest waste recycling
Bulk bag programs

E-Commerce & Fulfillment

Scalable packaging programs designed for high-volume fulfillment operations. Off-site inventory management, daily delivery, vendor consolidation, and cost-per-order optimization.

Off-site inventory management
Daily scheduled delivery
Cost-per-order optimization
Multi-size packaging programs
Returns packaging handling

Chemical & Pharmaceutical

Compliant packaging programs for regulated industries. Container reconditioning, pressure testing, documentation, and hazardous material packaging expertise.

Container reconditioning & testing
UN/DOT rated packaging
Full traceability systems
Clean room packaging options
Regulatory documentation support

Construction & Building Materials

Heavy-duty packaging for construction materials, building products, and raw materials. Oversized and custom-engineered packaging solutions for non-standard products.

Heavy-duty gaylords & crates
Oversized packaging engineering
Jobsite delivery
Pallet programs for heavy loads
Debris container programs

Frequently Asked Questions

Common questions about our custom packaging solutions.

How long does it take to develop a custom solution?

Typical timeline from initial consultation to program launch is 4-8 weeks, depending on complexity. Simple solutions (like switching from new to used packaging with scheduled delivery) can be implemented in as little as one week. Complex programs (inventory management with custom specifications and multiple locations) may take 6-8 weeks to fully design and implement.

Is there a cost for the initial consultation?

No. Our initial consultation and needs assessment are completely free with no obligation. We invest this time upfront because we believe in earning your business by demonstrating value before you commit to anything. If we cannot identify meaningful savings or improvements, we will tell you honestly.

What size business do your custom solutions work for?

We work with businesses of all sizes — from local operations spending $5,000 per year on packaging to large enterprises spending over $1 million. Our solutions scale accordingly. Smaller businesses might benefit from a simple buy/sell arrangement with scheduled delivery, while larger operations often need comprehensive programs with inventory management, recycling, and consulting components.

Can you replace our current packaging suppliers?

In most cases, yes. Many of our custom solution clients have consolidated from 3-5 packaging suppliers down to PackMesa as a single source. This simplifies procurement, reduces management overhead, improves pricing through volume consolidation, and gives you a single point of accountability. We handle sourcing of both used and new materials as needed.

How do you measure and report on program performance?

Every custom program includes regular reporting tailored to your priorities. Standard metrics include: cost per unit, total spend vs. budget, delivery on-time percentage, inventory levels, waste/recycling volumes, sustainability impact, and cost savings vs. baseline. Reports are delivered monthly with quarterly business reviews for in-depth analysis.

What if our needs change after the program is in place?

Our programs are designed to be flexible and evolve with your business. Your dedicated account manager monitors performance and proactively suggests adjustments. Volume changes, new product additions, seasonal scaling, new locations — all are handled as part of the ongoing program management at no additional cost.

Do you require long-term contracts?

No. While we offer contract options with the best pricing for clients who want long-term commitments, we also work on a month-to-month basis. We believe our service quality and cost savings are the best retention tools — not contractual lock-in. Most clients stay because the program works, not because they have to.

Can PackMesa handle packaging for products we export internationally?

Yes. We are experienced with export packaging requirements including ISPM-15 compliant wood packaging (heat-treated pallets and crates), export-grade containers, and packaging that meets international shipping standards. We can advise on material requirements for specific destination countries and ensure your packaging meets all applicable regulations.

Let's Build Your Solution

Tell us about your packaging challenges and we will develop a custom solution that fits your needs and budget. The consultation is free, the assessment is thorough, and the results speak for themselves.

Average client savings: 35% on total packaging costs. Average payback period: under 60 days.

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