How do you know that the packaging system you are purchasing offers the best possible protection for your product? Many companies today are using computer simulations to test packaging designs before they invest in thousands of new containers or pallets.

Computer simulations, which can reduce development costs and shorten time to market while providing the chance to explore "what if" scenarios and alternative materials, are new to the packaging industry, according to Joanne R. Zuzelski. Zuzelski, director of industry focus consulting for Altair Engineering (www.altair.com). She spoke at Dimensions 02, an international conference on transport packaging held recently in Anaheim, Calif.

Zuzelski shared how her company used computer simulations to help a leading plastic pallet manufacturer improve its development of a new pallet. The simulation software examined and then virtually tested a multitude of design variables, including impact studies and peak load capabilities. The tests aided in identifying the ideal materials for construction and the ribbing design best suited for the 21-pound finished pallet.

In another example, the company evaluated a design for a returnable plastic container for handling produce. Simulations examined the material composition, hinges, latches, ventilation- hole design, thickness and ribbing structure. Compressive load tests also were utilized to determine the optimum design.