Designers should keep in mind what happens after the packaging has fulfilled its purpose during its lifespan. Food packages become redundant immediately after consumption. Sustainability is therefore vital to consider in the packaging design process and to reduce wastage. Packaging reduces food wastage from manufacturing to consumption (Gustavsson et al. 2011). This reduction is the reason why designers need to find the balance between the quality of the package and the impact on the environment (Maffei & Schifferstein, 2017).
After all the design stages have been completed and the client approved the final packaging label design, high quality of artwork is prepared for the printing stage and is followed by the manufacturing of the packaging design process. With the continued documentation of the packaging design process, it was established that three designs options will be created to represent different aspects of sustainability and premium quality. The first is the generic coffee packaging shape in the form of recycled plastic material. The second is a cylindrical wax shape packaging that represents re-purposing and partial biodegradable aspects. The third is a dual packaging in the form of a glass bottle that can be re-used by purchasing the complete biodegradable refill sachets. To continue with the manufacturing stage of the process, South African Product manufacturing regulations need to be taken into account.
According to the Department Of Agriculture, Land Reform and Rural Development in the Regulations Relating to Coffee, Chicory and Related Products Intended for Sale in the Republic Of South Africa, also known as the Agriculture Product Standards Act state the following container requirements:
REQUIREMENTS FOR CONTAINERS AND OUTER CONTAINERS
(1) A container in which coffee, chicory or related products is packed shall
(a) Be manufactured from a material that –
(i) is suitable for this purpose;
(ii) will protect the contents thereof from contamination; and
(iii) will not impart any undesirable taste or flavour to the contents thereof;
(b) be so strong that it will not be damaged or deformed during normal
storage, handling and transport practices;
(c) be intact and clean; and
(d) be closed properly in a manner permitted by the nature thereof.
(2) If containers containing coffee, chicory or related products are packed in outer
containers, such outer containers shall –
(a) Be intact, clean, neat, suitable and strong enough; and
(b) Not impart any undesirable taste or flavour to the contents thereof.
(Department Of Agriculture, Land Reform And Rural Development, 2020)
All of the options comply with the regulations above and will be discussed in detail below. Each of the options has a one-way valve and has an eco-friendly paper label.
PACKAGING OPTION ONE
Recycled Plastic Bag
Recyclable plastic fulfils the requirements of food interaction regulations and has versatility in design and recyclable processes (The Pouch Shop, 2020). This packaging will be manufactured and purchased from The Pouch Shop. The package is made out of black recycled plastic material with a foil inlay and a one-way valve that contributes to the smell of the multisensory interaction experience. Suitable for fast turnaround products where shelf life is not an issue. They have a good water barrier and UV properties. The design is finished off with an eco-friendly paper label.
PACKAGING OPTION TWO
Wax Cylindrical Packaging
Packaging option two is manufactured through the brand itself with wax material which is made from petroleum such as paraffin candle wax which is the strongest type of wax and is used as the outer layer of the packaging. The wax is dyed with a black coloured oil soluble powder dye to give it an even colour another option is black crayons as it is also made out of paraffin wax. The candle has two wicks to ensure all of the candle wax is used up when lit. The first is wrapped on the inside of the candle wax shape and the second is at the bottom of the container. A foil sachet is placed on the inside of the wax container to protect the product. Covering the top of the wax container is a paperboard cap with a transparent one-way valve. As the wax is the outside layer the paper and wax sliding over one another creates a sealed barrier.
Steps to follow to manufacture the candle packaging: Melt some candle wax in a double boiler (a pot in a pot of water). Once the wax is melted you can add the black candle dye. Use a toothpick or “sosatie stick” to measure out a pinch of candle dye. This dye is highly concentrated therefore you only need a small amount. Stir gently until the candle dye has completely dissolved in the melted wax (Candle Deli, 2020). The wax is poured into a mould made out of an outer layer of glass and an inner layer cardboard container. Prep the mould with an oil layer on the glass. Wrap the long wick around the inner cardboard mould. Pour a two-finger wax amount into the glass container. Place the small wick in the middle until it completely sets. Place the cardboard mould over the wick and into the glass container. The wax is poured in a layered format with used coffee grounds in between, wait for the wax to start to set between layers. The used coffee grounds create a coffee smell sensory experience. The out layer of wax packaging will smell like the product on the inside and as the candle is lit the coffee aroma will spread through the house as a sensory reminder to the consumer to purchase the coffee again. Remove the wax packaging by placing the entire mould in an ice bath container, the wax will shrink away from the sides of the mould. After the wax packaging is removed from the mould a warm metal circle impression is pressed onto the outer layer of the wax to create a textured sensory touch experience.
The candle making supplies can be gathered from Candle Deli or The Factory Store. The foil inner layer bag can be purchased at any Plastilon or spice supply shops. The paper tube cap is made out of black 120 to 1200 grams thick paper material purchased at any craft shop with the one-way valve which can be purchased at Coffee Bags or Tricorbraun Flex, placed on the inside at the top of the cap. The design is finished off with an eco-friendly paper label.
PACKAGING OPTION THREE
Glass Cube Shape Packaging
Packaging option three is a glass bottle with a tin turn on cap. This packaging is manufactured by Consol. According to the Design for Recycling for Packaging and Paper in South Africa, it was established that glass can be recycled infinitely while it recollects the original properties during the process. It further never decays and the recycling saves energy and carbon emission reductions during the manufacturing of new glass packaging (Packaging SA, 2017). The transparent one-way valve is added to the top tin turn on cap. The design is finished off with an eco-friendly paper label.
The refill bio-based 300ml clear wood cellulose gusseted bags are purchased from Green Home. This bag is made out of biodegradable material which is a clear cellulose material made from renewable and natural FSC certified sustainable wood fibre (Green Home, 2020).
ECO-FRIENDLY PAPER LABEL
The eco-friendly paper label can be printed at Print it ZA who is an eco-friendly printing company based in Johannesburg, South Africa they offer Litho and Digital Printing. They are inspired by the core principles of eco-consciousness, they keep a close watch on every step a sheet of paper goes through within their facility. This green approach starts with their equipment, goes to their employees and extends to the consumer business. Go Green and Team up with Print It ZA, one of the eco-friendly printing companies that are here to turn the world into a safer place (Print It ZA, 2021).
TRANSPARENT ONE-WAY VALVE
101BR
The Biotre™ RENEW Valve is made from 100% renewable, plant-based material completely eliminating the use of fossil fuel-based plastic in the valve body. It allows the same off-gassing as their standard Heat Sealing Valves and provides the same superior freshness protection. The valve adheres to the polyethylene (PE) interior of a package via heat seal, just like our standard Heat Sealing Valves, and can be applied using existing equipment in the field. Supplied with filter (Tricorbraun Flex, 2020).
