Design Service

We have developed proven, environmentally friendly and commercially beneficial inflatable and transit packaging solutions for multiple sectors / industries. Our goal is to deliver a range of bespoke packaging solutions for each and every client; meeting their individual business requirements following a collaborative Design Process.
Our UK and Chinese design facilities translate our digital design concepts into samples to support Proof of Concept and the preferred final solution, pre-production.
The Design Process is adaptable and scalable, meaning lead times for relatively simple designs can be completed in a few weeks. Complex designs with challenging business, testing periods and governance/reporting requirements can take longer.

Automation for large-scale packaging lines and improvements in packaging performance has become one of GAIA’s main unique selling and focal points as we strive to be at the forefront of the quickly evolving packaging industry. We have successfully developed and deployed several automated inflatable packaging solutions into some of UK and Europe’s largest manufacturers and distributors.    
Our designs deliver innovative, unique and leading-edge packaging solutions by adopting the following design process:

Packaging Scope and Definition
Protective packaging performance, materials, distribution network, sustainability / re-usability etc.

Digital Design
Graphical images used to demonstrate alternate packaging solutions.

Sample & Proof of Concept
Samples are produced to ensure correct sizing and solution meet performance / business requirements.

Preferred Solution & Pilot
A pilot quantity of the preferred solution(s) are produced, tested and assessed to verify all performance criteria are met.

Independent Verification
GAIA will coordinate and manage any additional tests e.g. International Safe Transit Association (ISTA).

Refine & Final Approval
​​​​​​​Due to design complexity some solutions may have several iterations before final approval.
The Design Process is adaptable and scalable meaning lead times for relatively simple designs can be completed in a few weeks. Complex designs with challenging business, testing and governance/reporting requirements can longer.

A Collaborative Design Process

A Collaborative Design Process

Packaging scope and definition; digital design; sample & proof of concept; preferred Solution & pilot

Other services

The benefits of protective packaging

Environmentally Responsible

A fully recyclable product that also reduces external carton sizes - reducing packaging material and transport cost, waste and CO2 emissions.


Improved Protection

AIR|SHIELD™ innovative protective properties significantly reduce damage in the most challenging distribution networks.



All our products are reusable and recyclable. Unrivalled waste and transaction savings within closed loop supply chains. 


Simplified Handling

Delivered palletized either flat or on rolls, our solutions will increase your packing performance, reduce cost and increase productivity.


Reduce Storage Space

Minimal storage required compared to other solutions such as EPS or Styrofoam and reductions in carton SKU ranges, saving money and space.


Reduced Volumetric Size

Reduces volumetric dimensions by up to 30% - lower shipment costs of single parcels and increases pallet utilisation.


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