Reading Reading Esko Launches Cape Pack Prime: A Dual Solution for Packaging Efficiency and Sustainability

Esko Launches Cape Pack Prime to Cut Costs and Improve Packaging Sustainability

Esko has launched Cape Pack Prime, a cloud-based software platform designed to help packaging companies reduce costs and improve sustainability performance simultaneously. The tool uses 3D product models to automate the optimisation of packaging design and palletisation. By integrating carbon emission calculations directly into the design workflow, it aims to bridge the gap between operational efficiency and environmental goals, a key challenge in the industry.

The launch responds to growing pressure from sustainable packaging regulations and eco-conscious consumers. For packaging converters, achieving supply chain optimisation while meeting strict sustainability KPIs is a complex task. Carbon footprint tracking, now embedded in the design process, is becoming a non-negotiable part of modern packaging operations.

Intelligent Software for Smarter Packaging

Cape Pack Prime builds on Esko’s established Cape Pack software, transitioning it to a cloud-based platform for greater accessibility and computing power. Its core function is to analyse 3D models of products and automatically generate the most space-efficient and protective packaging and palletising solutions in seconds.

This automation significantly accelerates design timelines by instantly creating required CAD files, dielines, 3D models, and reports. A key benefit is the identification of “lightweighting” opportunities, where packaging material can be reduced without sacrificing strength—directly lowering material use, waste, and cost.

Quantifying the Environmental and Financial Impact

The platform’s value extends beyond basic design. It provides tangible metrics on performance by calculating estimated pallet loads and shipment volumes to optimise logistics. According to reporting on the launch, this capability can help reduce shipping costs by an average of 10 per cent by maximising cargo efficiency.

Most notably, Cape Pack Prime integrates a carbon emission calculation tool developed in collaboration with consultancy CarbonQuota®. This feature automatically measures the carbon footprint of a packaging solution at every stage, from material production to transportation. It provides companies with verified, consistent data to track against sustainability key performance indicators (KPIs) and comply with increasing regulatory requirements.

A Unified Approach to Data and Design

A major challenge in packaging development is the fragmentation of data across design, engineering, and sustainability teams. Cape Pack Prime addresses this by standardising methodologies and consolidating all relevant data within a single platform. This creates a consistent and auditable record for both packaging efficiency and environmental impact, replacing guesswork and disconnected spreadsheets.

By introducing carbon footprint considerations at the very beginning of the design process, the software promotes a “sustainability-by-design” approach. This shift allows brands and converters to make informed trade-off decisions early on, ensuring the final packaging solution is optimised for cost, performance, and environmental responsibility from the outset.