Removing plastic film from our cartons
In an effort to reduce packaging waste, we recently took on the complex challenge of eliminating the plastic overwrap film traditionally used on our tea bag cartons.
This required the complete redesign of the cartons as the overwrap previously provided a tamper-evident seal, added strength for shipping and ensured easy handling for the consumer. Our packaging team collaborated with various suppliers to test multiple solutions.
Of these, 17 box designs were put through a comprehensive process of compression testing, shipping simulations, on-shelf testing and handling and storage assessments.
After several iterations and refinements, our team succeeded in creating a packaging solution that maintained all necessary protections while significantly reducing material usage. The outcome will be more than 100 tonnes of plastic film saved per year, marking a meaningful step toward more sustainable packaging.