PACKAGING DESIGN: CLIPPER TEAS
Summary
This project explores the complexities of packaging design and production through the development of a product–packaging system that considers cost, logistics, distribution, marketing, product vulnerability, convenience, and ease of use. The brand CLIPPER TEAS and its emerging product Latin American Organic Instant Coffee serve as the design focus, resulting in a packaging system—primary, secondary, and tertiary—centered on appropriate material selection and sustainability.
Design concept/Stated purpose
The product concept is a CLIPPER gift box for coffee lovers who care about the planet and its people. Building on the brand’s success in tea and its commitment to ethical, organic products, the concept extends CLIPPER’s coffee range by presenting Organic Latin American Instant Coffee as a gift set with coffee sachets in a reusable tin, a cup made from ground coffee and sugar cane, all packaged in recycled paperboard.
The products: Organic Latin American Instant Coffee sachets, a tinplate storage box, and a coffee mug made from ground coffee
As the design primarily focuses on the primary packaging/unit, with a similar approach applied to secondary and tertiary packaging, this section introduces only the primary packaging.
The full packaging system design is detailed in the project report, available here.
The primary packaging
The Sachet
The sachet contains a single 15 g serving of coffee and is the only packaging component in direct contact with the product. It is designed to preserve coffee quality while ensuring recyclability, usability, and safety.
(Left) exloded view of the sachet's multilayer film, and (right) sachet film dimensions and graphics.
Material
PET/EVOH/PE multilayer film:
-
PET: durability and printability
-
EVOH: protection against oxygen and moisture
-
PE: reliable heat sealing,
Graphics & Information: Includes essential product information, certifications, and recycling iconography; detailed nutritional data is provided on the storage box.
Production: Manufactured through multilayer co-extrusion, lithographic printing, and vertical form-fill-seal processing. Design features include controlled headspace and a tear notch for easy opening.
The Tinplate Box
The box stores 28 sachets and provides additional protection against oxygen, moisture, and light. It carries all mandatory product and brand information on the back and serves as the primary carrier of CLIPPER’s visual identity. Its visually appealing design encourages reuse after the product is finished.
Material: Tinplate
Graphics & Information: In accordance with Regulation (EU) No 1169/2011, the box provides mandatory nutritional, ingredient, allergen, and country-of-origin information, meeting legibility requirements.
Production: Lithographic printing, lacquering and curing, die cutting, rolling and forming of the body with welded seams, deep drawing and curling of the lid and bottom, and final assembly by double seaming, with the lid fitted by form-fit.
(Top) isometric view of the tinplate box, and (bottom) tinplate box with instant coffee sachets.
Tinplate dimensions and graphics before forming of the box.
(Top) isometric view of the back of the tinplate box, and (bottom) mandatory information graphics of the product.
The Cup Insert
The insert stabilizes the cup inside the box by securing it in position through contouring of the cup handle. It consists of a bed and two walls, locked together by form-fit.
Material: Corrugated board (4 mm thickness)
Production: Die-cutting and creasing of corrugated board, followed by folding of the bed and form-fit assembly of the walls.
Design Considerations: The insert is designed to fit tightly within the box, preventing movement of both the insert and the cup.
(Left) front and (right) top view of the cup insert with the cup.
(Left) Dimensions of the assembled cup insert and cup, and (left) dimensions and die-cutting guidelines of the cup insert parts.
The Primary Corrugated Box
The primary corrugated box contains the tinplate storage box with coffee sachets and the insert with the cup. As the unit displayed on retail shelves, it communicates the contents while conveying CLIPPER’s visual and ethical identity.
Material
100% recycled corrugated board
FEFCO 427 · Testliner 1 · B-flute
Graphics & Information
The box presents essential product information and fully integrates CLIPPER’s visual identity, emphasizing aesthetics and ethical values. Distributor-specific information is included on the back.
Production
Lithographic printing, die-cutting and creasing, folding, gluing of flaps (lid left open), top filling, and final sealing with a branded sticker.
The Brand's identity
As reflected in the graphic design of the previously introduced packaging components, CLIPPER’s visual identity has been analyzed and integrated across all packaging elements. A summarized analysis is presented below.
(From top to bottom) primary/gift box with the products, isometric view of the closed box and back of the box with mandatory graphics.
Dimensions and die-cutting guidelines of the primary corrugated box.
Application is no longer available.
To explore the design and specifications of the secondary and tertiary packaging, as well as the overall design process, request the full report here.
Packaging Design & Management
September - October, 2024
#packaging_system
#brand_analysis
#material_choice
#sustainability