Lunch Packaging

Brian Russell

Exam expectationsPacked lunch containers is the theme for the design question on the 2013 written paper and this presentation is designed specifically to support this. Paper/card is the compulsory material so always expect questions in the exam to relate to this topic. This is often linked to a question on packaging. Packaging is also a topic on its own and you are expected to know about a range of packaging solutions and the materials and processes used.

What to design?

• The preliminary material tells us that the context for the designing question is: Packed lunch containers

• If you look back at past questions like this candidates were asked to design mainly using card

• Think about who the user might be - children, adults, such as office workers, athletes etc.

• Think about what might need to be contained – drink, sandwich, yoghurt, fruit etc.

Your problem?

Where to startPotentially this is a large topic to investigate so concentrate on:

• Paper and card containers

• The use of new materials (alternatives to oil based polymers)

The functions of packaging

• Protect

• Inform

• Contain

• Transport

• Preserve

• Display

I PICT PD

If you can remember these you can write design criteria, explain the purposes or functions of packaging

Best answers?

Purposes/functions Reasons

Transport It will be important to be able to easily transport the food from the shop to where you want to eat

Contain The food will need to be contained and may need to be separated – sweet and savoury for example

Preserve Keeping the food fresh and maintaining the correct temperature will be important

Function 1: ProtectThe packaging needs to protect the food from contamination but often needs to protect the user from grease. The outer layer in this case is made from carton board or solid white board. The card needs to be food grade.

Protecting the sandwichThis type of packaging protects, preserves and displays the product. These sandwich wedges are made from sustainable Kraft board with a 100% compostable liner and a window made from cornstarch. They are supplied flat for easy storage and assembly is simple.

Security

To avoid any form of tampering sandwich cartons are sealed so that customers are confident that the product has not been tampered with in any way.

Security• Pret a Manger use colour coded security labels so they can check

and remove stock which has been on the shelf too long. This is helping to protect the consumers from potential bacterial hazards.

Function 2: Inform• Most lunch packaging is generic and would not contain a great deal of

information. Windows are often a feature so that you can see what is inside. Windows are usually made from Cornstarch like the sandwich example shown earlier.

Key information• Nutritional information is found on some pre-packaged

food but you are unlikely to be asked to do anything more than suggest a space on the lunch container.

Symbols• Informing consumers that the food is suitable for vegetarians or vegans is important to many people.

There are a wide range of symbols used for this purpose and some are shown below.• You are unlikely to be asked to do more than suggest the position of such symbols on your container

Symbols • As lunch packaging is unlikely to be used more than once manufacturers are often eager to inform customers that it can be recycled. Variations of these symbols are often found on this type of packaging• You are unlikely to be asked to do more than suggest the position of such symbols on your container

Symbols• It is common to see an anti-litter logo printed onto the

packaging. The symbol on the right is the more usual Keep Britain Tidy version whereas the one on the left is from the Love Where You Live campaign

• You are unlikely to be asked to do more than suggest the position of such symbols on your container

Symbols• The FSC logo provides the consumer with a guarantee that the card board has been made from timber

which has come from a sustainable source.• The forest will have been evaluated and certified as being managed according to agreed social,

economically viable and environmental standards.

Symbols

The German ‘Green Dot’, has little environmental significance. It only means that the manufacturer has paid a fee towards the packaging recovery system in Germany. On lunch packaging this is usually shown in a single colour

Function 3: Contain• Food needs to be contained. This is particularly important if the food has strong flavours or is in small pieces. • The most common material used for this type of insert is PET. This tray has been vacuum formed. There are now

alternatives to oil based polymers based on plant starches

Alternatives to plastics• This container looks as if it is made from normal Kraft board. Many such

containers have a plastic lining and therefore are not compostable. • This version is from sustainably sourced paper board with a water-based coating,

made up with leak-proof webbed corners and fold-in flaps to give a secure closure.

Environmentally friendly• These sandwich wedges are fully compostable, being made from brown Kraft board with a compostable liner and PLA window (made from

cornstarch). • Grease proof lining like the previous example. • They are supplied flat and assembly is very simple.

Kraft board uses unbleached pulp so is more environmentally friendly than solid white board.

Environmentally friendly• These PLA Sandwich wedges are 100% compostable. • Made from clear PLA renewable plastic which is plant

based. • This is ideal for packaging as it starts to decompose very

soon after use.

Bucket meals• This approach to packaging lunch has been made famous by KFC. This waxed card solution

is only really suitable for food such as pieces of chicken. • KFC have been heavily criticised because the wood pulp has been found to come from

rainforests.

Function 4: TransportThis type of card container is one of the most popular children’s lunch containers and is often printed with decorative graphics. Solid white board is best if printing in full colour

Deli box• A more adult lunch container simply made from Kraft

board with a locking handle. Made from recycled fibres, this is an unbleached board which is a pale brown colour.

Handles• If the lunch container has a handle you will need to

consider anthropometrics• If you design your box to fit your own hand it would be

large enough for younger children

Deli box• A folded deli box, again, made from coated Kraft board.

• Designed to hold wet dishes such as curry, pasta etc.

• The corners are folded, then glued to prevent leaks.

• Locking tabs keep the carton closed

Flat pack

• To save space many food containers are produced to be stored flat and simply opened up into their final form.

Function 5: Preserve• Pizza boxes are very good examples of lunch containers which are very simple. • They are made from corrugated cardboard which is lightweight, stiff and a good

insulator so the food is preserved at the right temperature. • The layers also do a good job in protecting the consumer from grease.

Temperature issues

• Traditionally manufactured from expanded polystyrene, this type of food container can now be made from a biodegradable bio-plastic such as Ecovio L Foam.

• Foamed materials are great insulators

Aluminium trays• These trays are sealed using a foil lined card lid and provide a very cheap solution. • Whilst they can be recycled, in practice they are often not separated and just treated

as general waste.

Function 6: Display• This type of packaging is often displayed in refrigerated display

units and rely on the window so the customer can easily see the product inside.

• This window is usually made of cornstarch nowadays as it is compostable.

Display• Many suppliers brand their packaging. • In the case of McDonalds the designers were asked to

try to persuade the consumers that the products were made from high quality ingredients.

Appealing to the customer

• It will be important that the packed lunch container is appealing to the customer.

• This might be achieved using printing or clear windows.

Nets• Cardboard cartons are made from nets. • These flat shapes are printed, cut, then folded and glued

to create a 3D box.

Your net• Make sure that you can draw an accurate net which will glue together to make a

3D carton• This example uses folded corners rather than traditional glue tabs

Practice drawing• Practice drawing and making both the 2D nets and the

3D cartons

Practice drawing• This is a very popular net for children’s packed lunch containers. • Practice drawing and making this.

Sandwich wedges• Practice making sandwich cartons (or wedges)• Try designing and making your own nets

Adding dimensionsMake sure that you know how to accurately show the three main dimensions. Use projection lines then neat arrows which touch the projection lines. Measurements should be in millimetres.

Adding colourPractice applying colour with coloured pencils. Experiment with tone as this is a simple way to get a good effect.

Offset lithography• Flat aluminium plates (specially

treated) • Photographically exposed then

wrapped around roller• Exposed parts attract water• Non exposed parts allow ink to stick• Print onto plain roller to reverse

image• Transfers to card or other materials

This is the best process to specify for printing your container if you are using solid white board

Flexographic printing

• Uses a printing plate made of rubber, plastic, or some other flexible material.

• Ink is applied to a raised image on the plate, which transfers the image to the printing

Ink Trough

Impression cylinder

PaperFountain roller

Anilox roller

Printing cylinder

This might be the best process to specify if you are printing simple information onto Kraft board

Die-cutting

Die-cutting is the method cartons are cut out. In the packaging industry the cutter is known as a cutting forme. A rounded blade creases where the carton will be folded.

PlywoodFoam layer

Card to be cut

Blade

Final remindersBe prepared to:• Adapt your design for different lunch products• Target different groups of users – children, adults, athletes etc.• Draw 2D nets and 3D cartons• Apply colour and graphics

Remember:• The functions of packed lunch containers• Keep the design simple• Detail materials and construction details