In an industry where temperature excursions can lead to catastrophic product loss and regulatory non-compliance, precision engineering is paramount. While standardized shippers fulfill baseline needs, the escalating complexity of payloads in the paper and packaging industry, including medical, veterinary, and pharmaceutical sectors, demands bespoke thermal solutions. At Frontier Paper & Packaging, this challenge is met by a comprehensive design approach, spearheaded by professionals like CAD Designer Sam Sisson. Beyond thermal performance, Sisson embodies the blend of technical expertise and creative problem-solving essential for optimizing all aspects of paper-based packaging for the cold chain and beyond.
From Material Science to Structural Integrity
Sam Sisson’s path to designing custom packaging began with an innate curiosity for how things are made, evolving from constructing intricate forts from corrugate as a child to a formal education in the field. He holds a degree from Indiana State in Packaging Engineering with a minor in computer-aided drafting and manufacturing, providing the specialized knowledge required to navigate this highly regulated industry. His 7 years of professional experience offer the technical depth necessary for addressing not only thermal challenges but also core structural design considerations in diverse packaging applications.
For Sisson, every project demands a delicate balance of various design elements. He is proficient in a suite of industry-standard software, including AutoCAD, Autodesk Inventor, Artios CAD, and SolidWorks, enabling him to move seamlessly from initial concept to high-fidelity virtual prototypes. This expertise is a critical asset for developing compliant packaging that addresses multiple functional and aesthetic requirements.
Beyond thermal: An Integrated Design Approach
In modern paper and packaging, a successful design must integrate multiple components, all of which fall under the purview of Sisson and his team:
- Structural Design: Utilizing CAD, the team engineers custom corrugated and paperboard structures. This involves optimizing folding patterns, interlocking mechanisms, and material thickness to ensure the package provides maximum protection against impact, vibration, and compression. This also contributes to logistical efficiency by optimizing size and weight for palletization and freight.
- Material Selection: Sisson’s role extends to strategic material choice. In addition to our eco-friendly Biocooler materials derived from plant starch or wood fiber, his team advises on the use of different paperboards, finishes, and reinforcements to match specific product requirements—for instance, selecting the right-density corrugate for a heavy payload versus a lighter, recycled option for less sensitive items.
- Graphic Integration: While Frontier offers graphic design services, Sisson’s work in structural design ensures seamless integration with graphic elements. Using 3D mockups generated from CAD files, he ensures that graphics and print align perfectly with the physical structure, avoiding issues with creasing or folding. This integration is crucial for maintaining brand identity and ensuring the packaging acts as an effective “silent salesman.”
- Sustainability Optimization: A key focus for Sisson is advancing sustainable solutions across the entire paper and packaging portfolio. Beyond the Biocooler line, his team designs for the circular economy by minimizing material usage through light weighting, ensuring compatibility with recycling streams, and eliminating unnecessary components.
The Power of Comprehensive Packaging Design
The final validated shipper is the result of this rigorous, data-driven, and holistic methodology. It’s a testament to the fact that in the paper and packaging industry, every detail matters. The strategic integration of in-house CAD design at Frontier Paper & Packaging, guided by the expertise of designers like Sam Sisson, ensures that custom solutions are not just functional, but are engineered for compliance, efficiency, and broader performance. This commitment to precise, customized, and expert-led design is setting a new standard for passive packaging systems and general paper-based packaging solutions in the industry.
