Summary
Cappellaro Fruits, a family-run grape farming business in Brazil, sought to replace their existing bulky trays with a paper-based packaging solution. Their goal was to reduce their environmental footprint and cut costs while maintaining durability, visual appeal, and efficient storage. Our team developed a bespoke solution using corrugated cardboard produce trays, calculating the exact strength required to match the performance of their previous solution. These trays were durable, space-efficient, and could be transported disassembled, reducing transportation costs and carbon emissions. Additionally, the design incorporated Cappellaro’s brand identity, enhancing product visibility and appeal in retail settings.
The Challenge
Founded in the 1990s, Cappellaro Fruits is a family-run business specializing in grape farming in Brazil's Pernambuco region. Recently, they identified the need to replace their existing bulky trays with a paper-based packaging solution. Their goals were clear: reduce their environmental footprint, cut costs, and maintain the same level of product protection. Additionally, they needed the new packaging to be visually appealing to consumers and address the significant storage challenges posed by their previous trays, which occupied excessive space and drove up transportation costs.
Our task was to create a bespoke solution that met all these criteria—offering a cost-effective, sustainable packaging option that also improved operational efficiency.
The Approach
Our designers faced the challenge of developing packaging that could match the performance of Cappellaro's previous solution. It was crucial to maintain the same internal product capacity without altering the external dimensions, as these were vital for meeting palletisation requirements.
Using our PackExpert tool, we calculated the exact strength required for a pack, taking into account all physical constraints in the supply chain. With this information, we were able to design a corrugated cardboard produce tray which was as durable as the previous non paper-based tray, providing the necessary protection for the delicate grapes. Unlike their previous trays, the corrugated cardboard solution allowed for the trays to be transported flat, significantly reducing the number of trucks required for delivery. This not only lowered transportation costs but also cut down on carbon emissions.
Every aspect of the new produce packaging was designed with practicality in mind, ensuring it met the demands of storage and transportation. Simultaneously, we incorporated elements of Cappellaro’s brand identity into the tray design, enhancing the product's visibility and appeal at the point of sale. This approach strengthened the brand's presence in retail environments and ensured the packaging stood out to consumers.
The Result
Our comprehensive design strategy led to the successful development of a cardboard produce tray that perfectly aligns with Cappellaro’s environmental goals as paper-based packaging is made from a renewable resource and is fully recyclable. The new corrugated cardboard solution met all performance and logistical requirements while supporting the company’s commitment to sustainability. The bespoke packaging delivered significant benefits:
- Eliminated approximately 120,000 non-biodegradable containers annually.
- Prevented nearly 9 tonnes of non-biodegradable waste and around 63 tonnes of CO2 emissions from entering the environment each year.
- Reduced the number of trucks needed for delivery from 48 to just 3, cutting down on 45 trucks annually.
This project highlighted how thoughtful design can achieve sustainability without compromising on performance or efficiency.
