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The Challenge

 

Fresh produce packaging plays a crucial role in maintaining quality, reducing waste, and optimizing costs. A leading blueberry distributor faced a significant challenge: their traditional cylindrical packaging for blueberries was not flat-shipped, leading to excessive shipping costs and inefficient storage. The bulky packaging increased transportation expenses and ultimately raised the overall cost for retailers and consumers.

Our client needed an innovative solution—one that maintained the structural integrity of tube packaging while significantly reducing shipping costs.

 

Our Approach

Understanding the logistical and structural challenges, we engineered a flat-shipped tube packaging solution that combines convenience with cost-effectiveness. Our design focused on three key aspects:

  1. Space Optimization: The new packaging ships flat, reducing storage volume by over 60%, enabling more units per shipment, and significantly cutting logistics costs.
  2. Structural Efficiency: Using high-quality, lightweight yet durable materials, the tube packaging retains its cylindrical shape once assembled, ensuring blueberries remain protected and fresh, and the brand identity remains the same. The package is designed for easy holding in the palm, carried as a quick snack on the go.
  3. Easy Assembly: The innovative fold-and-lock mechanism allows for quick and hassle-free assembly, making it convenient for both retailers and distributors.

 

blueberry fruits packaging

The Results

The transformation from traditional tube packaging to our flat-shipped design yielded remarkable results:

  • 50% reduction in shipping costs, optimizing distribution efficiency.
  • Improved sustainability, with lower carbon emissions due to optimized transport.
  • Stronger shelf appeal, as the new packaging retained the premium look while enhancing functionality.
  • Retailer and distributor satisfaction, with an easy-to-store and assemble solution that streamlined inventory management.

 

Looking Ahead

 

With a growing emphasis on sustainability and cost-efficiency in the fresh produce industry, our flat-shipped tube packaging sets a new benchmark for smart, innovative design. By minimizing logistics challenges while ensuring product protection, we’ve successfully enhanced the efficiency, affordability, and sustainability of blueberry packaging.

For more information on how our packaging innovations can optimize your supply chain, connect with us today.