What did the job entail?

The pack needed to be smart and strong enough to protect the expensive and fragile product during transit, particularly to the US, RSL Steeper’s biggest market. The client ordered 1,015 packs with 500 to follow every six months.

How was it produced?
A top sheet was litho printed by Geneva print and sent to Smurfit Kappa’s Barnstaple facility where it was litho laminated on to E-flute corrugated board using a Tünkers machine to give a matt varnish and smooth texture. The slippery surface combined with loose fitting ensure that end users can open the box with one hand by lifting the lid and allowing the base to slip out. Designer Paul Lowes added tamper-evident strips, similar to rip strips found on shelf-ready packaging, that tear to enable access and reveal interference with the product.

What challenges were overcome?
Originally, RSL Steeper requested a plastic box with plastic fittings to support the product. However, it agreed that Smurfit Kappa’s idea of using corrugated packaging looked better while significantly reducing its use of non-biodegradable products.

What was the feedback?
RSL Steeper mechanical design engineer Dean Cowan said: "Smurfit Kappa delivered on all aspects of our brief and then some! From the tactile finish, through the tamper-evident aspect and the ability to be opened one-handed, the box has revolutionised the way we pack our high-value products and present our company."