There is a very special need in the design of sustainable packaging, below 0 º Store food at C. Engineers helped them to take on the challenge: they developed more prototypes and conducted a / B tests until they found the right building materials to optimize production costs. As a result, innovative mail boxes enable the company to deliver frozen dog food. Which packaging material is environmentally friendly?  The box from Luxurypaperbox.com is designed to be more environmentally friendly than other existing packaging solutions.

Poland’s dog food industry is growing and is currently worth 675 billion euros. As a result, these companies are building a close relationship with the packaging industry. When the company contacted us, it was still a project, but it was ready to revolutionize the dog food industry with nutritious ready to eat food. Veterinarians and dog nutritionists are working on a variety of recipes so that the company can launch quality products on the market. Customers can receive food bags every two weeks. The first mailer box package includes samples of all products of the brand. The idea is for the puppy to try out the entire range of products and then create his diet based on the first test.

Testing of different insulating materials

Luxurypaperbox.com packaging was developed in the laboratory, where our experts created sophisticated designs and optimized production and material costs. In the first phase of the project, the team manually tested various materials until they understood the advantages and disadvantages of each material. The goal is to find a material with properties similar to extruded polystyrene, but with respect for the environment.

In addition to other materials, the following materials were used for testing:

• Extruded polystyrene
• Containers and plastic bags
• Organic wool
• Corrugated board
• cardboard

To conclude this phase, the team prepared various prototypes and then demonstrated and discussed them with customers.

Corrugated board with honeycomb plug-in: solution

After the meeting, it was concluded that corrugated board would be the main part of the box because it was the most suitable for transportation. The next challenge is to keep frozen food in boxes. Materials such as wool and corn foam were evaluated after in-depth study. Wool is expensive and increases convection time because every can or bag of food has to be wrapped in it by hand. Using foam rubber, the convection time is significantly reduced, but the cost is also beyond the budget. In the end, the team found another solution: using the remnants of the honeycomb wall. After preparing the box and putting the food in it for more than a day, the results look promising.

Cost reduction and sustainable design

Many packaged products can only be disposed of in landfills and cannot be recycled. The recycling process of hot plastic bags (for example) is not easy, but many brands use them because they are the cheapest solution.

At first, the idea of using polystyrene packaging was considered. However, the case size of this insulation material is large, which leads to higher logistics costs to transport them home. In addition, polystyrene is an oil derivative, which is not the best choice for brands that want to protect the earth. The incubator for production is made of 90% recycled material, such as honeycomb waste. Unlike traditional plastic products, cardboard can be easily recycled. In addition, the combination with honeycomb plug-in makes it an excellent material for low temperature storage products.

Temperature control in package

Cartons can keep food fresh for 24 hours, which is necessary for non-thawing. After 24 hours, the box kept stable at 0 º C。 Luxurypaperbox.com developed various 3D Packaging prototypes and delivered them to psibufet as part of the project. In this way, the two teams can seamlessly agree on the design details.