Antalis Packaging has developed a three-part packaging concept to demonstrate its recently launched Premium Packaging service, combining moulded fibre, folding carton and corrugated packaging to protect a fragile chocolate egg through the postal network.
Developed entirely in-house, the pack comprises a custom moulded pulp insert, a presentation carton and an E-flute corrugated mailing box.
The moulded pulp component provides shock absorption and features an integrated locking closure to hold the egg during transit. It is housed inside a presentation carton produced from 300gsm Keaykolour Lipstick board, featuring curved profiles, layered folds and a glue-free locking design.
The presentation carton was digitally printed using an HP Indigo 12000 Digital Press and cut on a Kongsberg X24 Digital Cutter. White graphics were printed directly onto the coloured board using a single-colour process.
For distribution, Antalis developed a lightweight E-flute corrugated mailing box around the dimensions of the presentation carton, eliminating the requirement for additional void fill. The outer pack incorporates a peel-and-seal closure and tear strip.
Sustainability considerations were incorporated throughout the design. The moulded pulp insert is recyclable and biodegradable, the Keaykolour board is FSC-certified, while the E-flute outer carton is manufactured using sustainably sourced fibre and is recyclable.
“Using a chocolate egg gave us the perfect opportunity to demonstrate how structural packaging design can solve a genuine logistical challenge whilst still creating a memorable brand experience,” said Verity Mottram, Creative Design Lead at Antalis UK. “Every design decision was carefully considered, from the protective moulded pulp insert through to the presentation carton and e-commerce box.”
The project demonstrates Antalis’ Premium Packaging service, which covers structural and graphic design, material selection, prototyping, production, stock management, fulfilment and distribution.
