Shelf Ready Tapeless Pack

This customer is passionate about the environment and wanted to reduce their non-recyclable waste impact by finding an alternative design for the closure of their shelf ready packing to remove the need for tape. Cost was also a factor for the customer, so a solution that both removed the need for tape and didn’t significantly increase the box price was required. In total 5 case sizes with an annual combined usage of 436,000 boxes was required.

The customers’ existing design consisted of an SRP 0201 with a standard cut out sausage lock base, which was manufactured on our TCY part rotary casemaker.

The new design maintained the SRP tear line and sausage lock base, but modifications were made where the SRP tear line became curved, paired with the introduction of the Speedi-Flare 9 rule type to improve the tear quality, along with the sausage lock changing to a hinged design to reduce the amount of unwanted excess trim which is a common occurrence on part rotary casemakers.

To solve the main objective of a closure that doesn’t require tape, a modified envelope style close was used. The purpose of this style was to create a closure that clicked shut with a small push and then stayed shut during transport.

A simple contrast two colour print was used to ensure visible branding and eye-catching shelf appeal.

The design successfully removes any need for a taped closure, with the envelope top providing a satisfying click. Further to this, designs which feature an envelope closure were traditionally a three-pass manufactured process (printed, then flat-bed die-cut and then glued), but introducing a hinged style sausage lock base, along with modifying the envelope closure to require less waste trim, we were able to re-route production.

The customer enjoyed an annual saving of c.£1500 by removing the tape and 540kg of  non-recyclable waste was eliminated from the customer’s supply chain every year.