Optimizing Packaging Design to Reduce Waste Using Polyhedral Geometry

and Fundamental Calculus

AD. Punatar*

*Aaditya Punatar
Billabong High School, Mumbai, India
[email protected]

SUMMARY
From manufacturing to delivering, every good needs proper packaging, but the waste created post-delivery
threatens the environment. Nature offers several answers to the challenges of maintaining sustainability in this
huge industry. Fruits optimally pack their delicate, fragile seeds, like pomegranate. Taking inspiration, the project
uses biomimicry in addition to mathematical concepts like polyhedral geometry as a solution to optimal packing. I
studied the geometry of various presently available packages, examined the geometry of nature, and
experimented with innovating a design of packages that can be most optimum from economic, sustainability, and
logistic viewpoints. The conditions for the appropriate design included a design that tessellates and has a good
volume/surface area ratio. To satisfy this condition, I formulated an expression linking dimensions of the boxes
and cans using calculus. Moreover, I brought to light an innovative shape for packaging—an icosahedron—which
proved an effective solution.

KEYWORDS
Biomimicry, Calculus, Packaging, Polyhedral Geometry

INTRODUCTION
We are presently living in a world where the use of science and technology play a vital role in our daily life,
whether it’s in the field of computers, textile or the field of packaging. Today, individuals meet their daily needs
primarily through products purchased from traditional brick-and-mortar stores or via e-commerce platforms.
Consequently, packaging has emerged as a vital aspect of contemporary commerce.
Packaging is a science of enclosing and protecting products for identification, distribution, storage and sale. It
involves the use of materials, methods and machinery to develop and produce the packaging system. These
systems can be categorized into three main types: primary packaging, which directly encloses the product;
secondary packaging, which groups primary packages; and tertiary packaging, which is used for bulk handling
and transportation. Each level contributes to the overall packaging waste, which has become a significant
environmental issue.

With advancement in packaging also comes the significant damage technology does to the environment. To
enhance the marketing aspects, firms sacrifice optimization of packaging materials which makes packaging a
significant contributor to waste. This is a highly threatening case of misallocation of resources. Most of the
packaging produced today has given function, but when the content of the goods is used, the packaging material
loses its usefulness and is treated as garbage. The rate of amount of package waste landfill is increasing year
after year. As shown by OECD Global Plastics Outlook, despite recycling efforts increasing from 9% in 2019 to a
projected 17% by 2060, the majority of plastic waste will still be landfilled (50%) or mismanaged (15%)

As per the result of a local survey done by me in the project, 54% of the people throw the product with the
packaging away. This growing trend underscores the urgent need for alternative solutions that address not only
the choice of materials but also the design of packaging itself to minimize waste.

Given these challenges, the focus of this research is to explore innovative packaging solutions that reduce
environmental impact. By mimicking natural geometries through biomimicry and applying mathematical tools such
as calculus and polyhedral geometry, this project aims to develop packaging designs that are not only
dimensionally optimized but also economically viable and environmentally friendly. Minimization of waste, rather
than relying solely on reusing, recycling, or disposal, is the preferred strategy. This study aims to contribute to
sustainable packaging practices that reduce waste while maintaining functionality and cost-efficiency.

1
METHODS
Determining the Length of Square to Cut from a Cuboid

Differentiate V with respect to x and keep w and l constants

Volume of Cuboid: V = (l−2 x ) ( w−2 x )( x ) 3 2 2
¿ 4 x −2l x −2 w x +lwx
dV 2
=12 x −4 lx−4 wx+lw
dx
At stationary points, the volume will reach maxima or minima when 1 st
Derivative = 0
2
0=12 x −4 lx−4 wx+lw
Using Quadratic formula:
4 (l+ w ) ± √ 16 ( l+w ) −4 ( lw )( 12 )
2
x=
2 ( 12 )
lw ± √ l 2+ w2−lw
x=
6
Find the second derivative to find maxima/minima
2
d V
=−4 √ l + w −lw
2 2
2
dx
Since the second derivative is less than 0, it is a maximum.
Figure 1.1 Thus when,
( l+ w )−√ l2 + w2−lw
x=
6
The volume will be at its maximum

Deriving the Height-Radius Relation for Minimum Surface Area

V
Given: V =π r 2 h ⇒ h= 2
πr
2
Total Surface Area: T . S . A=2 π r + 2 π rh=2 π r + 2 π r
2
( πVr )
2

2 2V
¿2π r +
r
Differentiate Surface Area with respect to r:
dS 2V
=4 π r− 2
dr r
At stationary points, the Surface Area reaches maxima or minima when:
Figure 1.2 1st Derivative = 0
2V
0=4 π r− 2
r
2V
⇒ 2
=4 π r
r
Multiplying both sides by r 2 : 2 V =4 π r 3
Simplifying: V =2 π r 3
Find the second derivative to find maxima/minima
2
d S 4V
2
=4 π + 3
dr r
Substitute V =2 π r 3 into the equation:

2
 2
d S
=4 π +4 ( 2 π r ) =4 π +8 π=12 π >0
3
2
dr
Thus, this is a minimum.
Therefore, the Surface Area is minimum when:
Volume¿ 2 π r 3
Or: π r 2 h=2 π r 3
h=2 r

Determining the best solid figure for packaging

The best shape for packaging should have the following qualities:
1. Surface/Volume Ratio should low (calculated using formulas)
2. The 2D shape of the respective solid should be tessellating (for better storage)
3. It should be attractive. (geometric symmetry, higher curvature, more edges/complexity)
RESULTS AND DISCUSSION

For a cuboid package, SA/V ratio is minimum when

( l+ w )−√ l2 + w2−lw
x=
6
For a cylinder package, SA/V ratio is minimum when h=2 r .
Table 1.1

Name of solid Features of optimal design

Surface: Volume Tessellation Attractive
ratio for unit
volume
Cuboid 7.39 Exists Lowest in symmetry and balance due to
unequal sides.
Tetrahedron 7.21 Exists Simple but less symmetric and proportionate
than the others.
Cube 6 Exists Symmetry but less complex.
Octahedron 5.72 Exists Symmetry and balance, though with sharper
edges.
Cylinder 5.535811 Does not exist Symmetry and smoothness but less efficient
and less balanced.
Dodecahedron 5.31 Does not exist High symmetry and a connection to the
golden ratio.
Capsule 5.251 Does not exist Moderate smoothness, less symmetry than
perfect polyhedra.
Icosahedron 5.148 Exists Very high symmetry and efficient in terms of
surface area and volume.
Sphere 4.83598 Does not exist Maximum symmetry, smoothness, and
optimal surface-to-volume ratio.
3
Based on the above conditions, an icosahedron is the most suitable structure, a conclusion supported by its
presence in nature. This geometrical form is a prime example of biomimicry, where nature’s designs inspire
human solutions. Viruses, for instance, utilize icosahedral shells to maximize the volume they can enclose,
efficiently housing the maximum amount of RNA. Similarly, radiolarians—marine organisms—possess icosahedral
structures that enable them to hold air, enhancing buoyancy and helping them remain suspended in water. These
natural instances demonstrate the efficiency of the icosahedron in optimizing space and function, making it a
model for innovative design.
These innovative designs and changes to dimensions can massively reduce packaging waste. On modifying the
dimensions of a common glass jars (height from 13.8 to 7.5 cm and radius from 2.7cm to 3.75cm), you save 16
cm2 of surface area. On using an icosahedral box instead of a cuboidal box of the same volume(330cm 3), I found,
180 cm2 worth of packaging surface area could be saved.

Even the smallest changes can significantly reduce packaging waste, making a powerful difference for our planet
and future generations.
CONCLUSIONS
In this paper, we have arrived at two relations for efficient SA/V ratio for both cuboids as well as cylinders.
Moreover, we generated 3 conditions, for an appropriate packaging design, and applied it on 8 different solid
figures. On arriving at the conclusion, that icosahedrons are a better packaging solid, we also explored on the
presence of icosahedrons in nature. In the future, I also aim to introduce material science and geometry of
materials/atoms to reduce packaging waste.

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