Buttermilk- a new design for a custom machine

A technical challenge posed by a luxury fudge company to create a specialised box to work for an automated packing machine

Buttermilk A-frame foiled packaging

Buttermilk have a heritage as a longstanding artisan manufacturer of the UK’s finest luxury fudge. They are also one of our most forward-looking customers and constantly challenge themselves and their suppliers to make ongoing improvements to products, service-levels and the representation of the brand.

Despite the popularity of its pre-packaged luxury fudge range, the company contacted us when they required a redesign project to look at technical changes that could be made to improve the structural design of their packaging.

We were required to participate in a technical design process in collaboration with the customer’s production lead and their chosen machine manufacturer.
Having commissioned an auto-packing line, the design of the carton had to be carefully considered to allow for this process. The creasing and perforation used for the construction had to be carefully designed and developed to allow for seamless erection, folding and gluing of the pinched A-frame top and the skillet bottom.

Our technical production team worked directly with the machine manufacturer and Buttermilk’s manufacturing team to design and develop multiple pre-production samples and then full production prototypes through multiple iterations to get the design signed off.

Buttermilk A frame-back-closeup-msp

A rewarding and successful project ultimately produced a carton which was indistinguishable to the consumer but was cheaper to produce and able to be packed in much greater volumes at hugely increased speed and efficiency.

Sometimes a project doesn’t need to involve a full redesign, a minor but well thought out change to the packaging construction might bring about a huge benefit in terms of productivity and revenue.

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