Objective In the process of traditional packaging design, less matching is considered between the product and logistics. This causes the waste of logistics cost. In order to solve this problem, the existing packaging design process needs to be improved. Methods First of all, based on the analysis of the turnover links in the lifecycle of the products, using the reverse analysis of logistics links, the maximal external dimension series of the products were determined by module division. Then, local shape and structural design was conducted using the mapping function of Pro/E; Sensitivity analysis of volume was performed using behavioral modeling method. Finally, the shape was optimized, and the volume and filling height were determined. Results The packaging design process after optimization utilized digital design methods such as modulus segmentation, behavior modeling and sensitivity analysis. The design process was greatly simplified, and the design results were helpful for reducing the cost of logistics. Conclusion The new design process established a reasonable connection between product parameters and logistics. Thus the results were more reliable and the blindness of traditional design process was reduced. At the end, the design efficiency was improved.