Itsu 3-Cavity
Meal Tray
Breaking boundaries with Halopak
This first-of-its-kind design was highly tested with multiple iterations and broke the boundaries of what we thought was possible with HALOPACK®.
The challenge
Alexir was engaged to deliver a completely new high-volume line for Itsu, (famous for their flavour-packed pan-Asian pre-made meals) within seven months. The requirement was a triple cavity MAP board tray that would hold ingredients like rice, noodles, protein, vegetables and a sauce.
This format, with three separate cavities, had never been created before, and at first, we weren’t sure it was possible. We had previously been asked to create compartments using a single piece of board and discovered it couldn’t be achieved.
Requirements:
The solution
In collaboration with Alexir, HALOPACK® & our industrial parts partner Proseal, an initial idea was tabled, and we got to work, agreeing on a 2-piece HALOPACK® design that allowed for new possibilities.
Itsu were very keen to get the pack right to be fit for purpose, but also to stand out on shelf with the graphic design, so there were a lot of design changes to the profile, and many white samples created. Final design changes and approvals were conducted with the customer in the studio to ensure the design met the exact specifications for approval. When approved, Proseal needed to design and manufacture the original trial tool to prove the concept – it worked.
We then had to test the manufacturing at high speed and high volume, so Proseal developed a partial tool for the full production team that was tweaked until we achieved success. The full production tool was given the green light ahead of schedule, and we were able to commence full production for launch in good time.
The result
Working in collaboration with the client and Proseal we were able to launch an entirely new product to market in less than seven months, leading with sustainable innovation that resulted in the delivery of a new HALOPACK® format that was not only sustainable, but airtight and truly stood out on the shelf.
Divisions involved
This creative project utilised the skills of two Alexir divisions, as well as our partners.
Design development of tray and sleeve through multiple white samples.
Trialling and development and production of final triple cavity HALOPACK® design in collaboration with Proseal.
A note from our team
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