Packaging manufacturers can be guilty of over complicating retail-ready packaging when in truth, a simple approach is often the most effective. Our work with a highly regarded UK food manufacturer is testament to this mindset.
The business approached Colton Packaging as a result of our expertise within the food manufacturing sector. Our team was asked to design a retail-ready snack tray which doubled up as a transit box to protect food during transportation.
The final solution needed to be eye-catching enough to encourage sales of the product on supermarket shelves, while at the same time keeping packing operations simple and streamlined for the manufacturer, maintaining its rigidity for palletised distribution.
Our team needed to work within a set budget, so choosing the right board grade was crucial. Balancing performance with efficiency was critical for the customer throughout this project as they sought to achieve a snack tray that would work harder from pallet to shelf.
Using our palletisation questionnaire, we were able to identify a board grade which would offer suitable strength for stacked palletised distribution, without over-specifying the material. A B-flute board was selected for its compression strength, perfect for stable pallet stacking. This particular board grade would also protect the contents and be easy to handle and open in-store.
The solution needed to be designed with manual packing in mind, with a structure that was intuitive and quick to erect. We designed a one-piece die-cut solution without the need for additional components. This design choice reduced packing time, while maintaining consistency across the packaging’s overall presentation.
A perforated tear-off lid made the case retail-ready upon delivery, with replenishment simple for staff. No decanting or secondary display materials were required and the retained back panel created a strong billboard area for the brand and its messaging, even when the tray was low on stock.
A curved front cut line was introduced to provide aesthetic and functional benefits. Aesthetically, this design softened the overall presentation and elevated shelf presence. Functionally it improved product reach and made it easier for consumers to remove items, with the front wall remaining intact.
Considered details such as these elevated the consumer experience without over-complicating the manufacturing process for a single die-cut design.
Overall, our solution delivered the following benefits for the customer:
This project highlights how thoughtful, structural design can improve product presentation and operational efficiency for retail-ready packaging, without adding unnecessary complexity for retailers or manufacturers.
Our client was able to realise their initial goal of designing a retail-ready snack tray that will work harder from pallet to shelf, while being efficient with their use of materials and remaining within budget.
If you’re a food manufacturer with a need to streamline your retail-ready packaging, then our design experts are here to help.
We’ll understand your budget and wider project goals, before walking you through our palletisation questionnaire to design the perfect solution.
