AI-Accelerated Engineering Platform

Engineering Intelligence
for Packaging Design

AI + physics-based engineering platform that helps packaging teams cut design cycles from weeks to minutes — in an industry still dominated by trial and error.

Request a Demo See the Platform
100×-1000×
Faster design cycles
$1T+
Global Packaging Market
15×
Average ROI
HookePak · Analysis
StructureFEFCO 0201
Board gradeBC Flute · 44 ECT
Required BCT780 N
Predicted BCT812 N ✓
Pallet efficiency+6.4%
CO₂ reduction−12%
Structural margin
AI: BC-38 meets the minimum target at lower weight — BC-44 provides more structural margin for higher stacking demand.
Industry experience from
Platform Preview

What the platform looks like

An illustrative engineering workspace for corrugated packaging decisions — from product input to structural analysis, board-grade comparison, and pallet planning in one view.

📦 Active Design 📊 Board Library 🧾 Reports HookePak · Build 9
HookePak logo HookePak
Design
⚙️ Engineering Analysis Live
📐 Geometry Input
📋 FEFCO Library
Optimisation
📊 Board Grades
🚛 Pallet Planner
🌱 Sustainability
Tools
🤖 AI Assistant
📁 Projects
Counter-top Appliance — Shipper Box
FEFCO 0201 · Double-wall corrugated · Updated just now
Predicted BCT
812 N
↑ 4.1% above target
Board Weight
650 gsm
↓ 8% vs baseline
Pallet Efficiency
78%
↑ +6.4% gain
CO₂ Estimate
1.2 kg
↓ −12% vs prev
Board Grade Comparison AI Ranked
GradeECTFluteScore
1BC-4444BC
92
2BC-3838BC
74
3C-3232C
55
AI: BC-44 exceeds required BCT by 4%. BC-38 also clears the 780 N target at lower weight — consider it where stacking margin requirements are lower.
BCT Performance Prediction Physics Model
540N
C-32
792N
BC-38
812N ✓
BC-44
950N
DW-48
1080N
TW-55
Required: 780 N — red dashed line
Pallet Utilisation Optimised
Before
71.6%
After
78.0%
Existing Gain Empty
AI Design Assistant Active
U
What's the lightest board grade that still meets BCT requirements?
AI
BC-38 is the lightest grade currently meeting your 780 N target (predicted 792 N). If stacking exceeds 4 pallets, recommend BC-44 for extra margin.
U
CO₂ difference between BC-38 and BC-44?
AI
BC-38 is approximately 9% lighter per unit — meaningful carbon reduction and aligns with PPWR material targets.
Concept UI · For illustration purposes · Actual interface may vary
3D FEA Engine

Drop your design. Define your loads. Get a full 3D simulation.

HookePak's simulation engine replaces physical BCT test iterations with live finite-element analysis — delivering stress fields, deflection maps, and safety factors in seconds, not weeks.

01
Input
Drop Box Design
02
Configure
Define Your Loads
03
Output
Full 3D Simulation
Box Geometry
⬡
Drop your .step / .stp / .box
file or click to browse
✓
RSC-B2-240×300×180.step
3 plies · EB-flute · 180gsm liner
Quick Presets
Load Configuration
Compression Load 2400 N
Load Rate 5 mm/min
Stacking Layers 6
Board Grade
Simulation Mode
3D STRESS FIELD — VON MISES [kPa]
—
—
—
—
—
HOOKEPAK FEA — BCT ANALYSIS — VON MISES STRESS F = 2,400 N ↓ UPPER PLATEN — RIGID BODY BULGE LOWER PLATEN — FIXED 980 kPa 735 490 245 0 kPa σ_vm Peak stress at corner Low stress mid-panel Safety Factor SF = 1.12 ✓ Max deflection: 2.16 mm · Board: EB Flute 180gsm · BCT prediction: 2,688 N
Example output — BCT box compression FEA, Von Mises stress field
Configure your design above and click Run Simulation to generate your own
Initialising solver…
Peak Stress
—
kPa
Max Deflection
—
mm
BCT Prediction
—
N
Safety Factor
—
× SF
Tests Saved
—
iterations
Load–Deflection Timeline
T = 0.00s
0s25%50%75%Peak
Solver Log
[SYS] HookePak FEA Engine — ready
[OK] WebGL2 solver initialised
[SYS] Awaiting geometry input…
🧪
~73% fewer physical tests required
This run replaces 18 BCT lab iterations — saving est. £4,200 and 6 weeks of test time
Product Demo

See the early HookePak prototype

Watch how an early HookePak prototype takes a product description to an engineering-backed packaging recommendation in under two minutes.

The Challenge

Packaging design is still slow and fragmented

The packaging industry still relies on trial-and-error engineering — disconnected tools, weeks-long test cycles, and no integrated structural intelligence.

01
✏️

Design Tool

Initial geometry in CAD

›
02
🧪

Physical Test

BCT lab testing

›
03
🔄

Redesign

Manual iteration

›
04
🧪

Retest

Back to the lab

›
05
✅

Production

Weeks later

⏱

Slow design cycles

Bespoke packaging takes weeks. Physical test → redesign → retest loops dominate workflows, blocking faster product launches.

🔧

Fragmented tooling

Design, structural analysis, pallet planning, and sustainability checks live in separate systems — no integrated engineering intelligence.

📦

Conservative material decisions

Without structural insight, engineers over-specify board grades — burning material cost and adding unnecessary weight and carbon.

📋

Rising regulatory pressure

EPR and EU PPWR are forcing material optimisation and recyclability targets, while existing tools offer no sustainability estimation.

The Solution

One intelligent platform for structural packaging decisions

HookePak combines engineering rules, packaging intelligence, and physics-grounded ML models — initially focused on fast corrugated decision support, with deeper simulation capability expanding over time.

⚙️

Structural Simulation

Physics-based analysis of box compression and stacking performance. Predict BCT, stacking response, and failure risk earlier in the design process.

📊

Board Grade Optimisation

AI-driven material selection to reduce cost and weight. Compare candidate board grades and rank them by structural fitness and efficiency.

🌱

Sustainability Estimation

Carbon and recyclability metrics integrated directly into the design workflow. Meet EPR and PPWR requirements without additional tooling.

🚛

Pallet Performance

Optimise logistics and stacking efficiency at pallet level. Improve utilisation, reduce shipments, and lower warehouse costs simultaneously.

Under the Hood

Engineering Intelligence Platform

Purpose-built packaging intelligence layers combining domain rules, calibrated physics, and ML-driven decision support — engineered to compound over time.

🤖
AI Design Assistant
Workflow guidance, FEFCO selection, and board-grade recommendations
↓
📚
Packaging Intelligence Engine
Material database, design rules, and packaging-specific domain knowledge
↓
⚡
Surrogate ML Models
Fast BCT and stacking predictions for day-to-day engineering decisions
↓
🔬
Physics Simulation Layer
Calibrated offline simulation generating validation and training data
↓
🗄️
Packaging Performance Dataset
Performance data linking geometry, materials, and structural outcomes
🔒
Physics-grounded intelligence
Built on engineering models, not prompts alone
🧱
Packaging-specific workflow
Domain rules embedded into decisions
📈
Compounding data advantage
A growing performance dataset over time
Market Opportunity

A trillion-dollar industry with outdated engineering tools

$1T+

Global packaging industry with ~4–5% CAGR

$450B+

Combined corrugated + paperboard packaging opportunity

💡

Thousands of packaging plants worldwide. Even small material optimisation improvements create significant value per plant. HookePak’s initial wedge is corrugated structural decision intelligence, with expansion into the broader corrugated + paperboard category over time.

Value Creation

Multiple value drivers, not just material savings

⏱

Engineering Productivity

100× faster

Accelerate design evaluation and eliminate weeks of manual iteration and physical rework cycles

📦

Material Optimisation

3–10% savings

Reduce over-specified board grades through structural insight, cutting material cost and weight

🚛

Logistics Efficiency

Up to 2×

Better pallet utilisation reduces total shipments and warehouse operating costs significantly

🌱

Sustainability Compliance

Enabling

Lighter packaging meeting ESG targets, EPR requirements, and PPWR regulations

Measurable impact across the full packaging workflow

From faster engineering cycles to material reduction, logistics gains, and sustainability compliance

10–50×

faster than traditional methods

About

Built from the inside out

🏗️
The Founder
Aerospace Engineer · Packaging Industry Specialist

HookePak was founded by an aerospace engineer with over 14 years of experience in modelling, simulation, and engineering software — including deep exposure to the packaging sector through major enterprise deployments. The founder has first-hand insight into the inefficiencies in packaging engineering workflows, having worked directly with leading manufacturers and consumer brands.

The platform is being developed in close dialogue with the market, ensuring it is grounded in real engineering challenges and commercial workflows while the product matures.

14+ years engineering Aerospace background FEA & simulation AI & ML Packaging industry Enterprise software
Industry relationships built across
Email us
[email protected]
or use the form below
Get in Touch

Ready to transform your packaging workflow?

Request a private platform demonstration or start a conversation with the HookePak team.