Operating as a Covid Secure Manufacturer


Cider manufacturer introduces new e-commerce range

Case Study - Design Innovation

Cider manufacturer introduces new e-commerce range


  • To develop a range of e-commerce home delivery packs
  • To create a common range to enable ease of packing
  • To support new e-commerce sales range as a result of Covid-19


To simplify this new packaging line, it was important that the packaging solutions were fit for purpose but also ensured the product was easily packed and protected.

Customer requirements demanded that the range was created as quickly as possible to allow the despatch of the new ecommerce products speedily.

Initially, the customer gave a clear brief on the size and shape of products to be shipped which resulted in the creation of a small, medium and large tamper proof pack, and a 12 x 500ml tamper proof pack.

Our customer was happy to be guided by our professional knowledge to make appropriate recommendations and present designs that allowed them to facilitate this new line of business.

Due to the overwhelming success of the initial range a further two products we added – a 20 litre BIB (Bag-in-a-box) shipper and a 48 x 500ml can shipper – to allow greater opportunity to meet online customer demands.


Each of the designs is the same style of tamper proof, full floored, three point glued case which gives superb stability and strength to accommodate weighty products.

To facilitate speedy conclusion of the initial switch to online retail, so that the newly added e-commerce range could commence, the packs were initially made without print, however they are now one colour printed with product information and recycling and handling instructions as well as FSC approved.

Each of the packs are manufactured from BE150KT, with double side tape applied to aid the speed of packing. They have sharks tooth, zipper tear tops to give the customer an easy and efficient way of opening the pack upon receipt.

The packs are delivered to the customer each week in pre-agreed quantities in a flat pack format to ensure delivery efficiencies were achieved.

All elements of the pack are 100% recyclable giving an ecommerce pack that not only ensures the product is protected, but that the customer can easily dispose of the packaging through most kerbside recycling facilities.

Facts and Stats:

Over 15,000 packs delivered in just two weeks from six lines

Fully recyclable by the consumer through typical recycling channels

Scope to develop the range further both in the current market environment and beyond for this customer and others