The constructional designers created a profile of the outer cover and two inner packs from one piece of folding box board. This reduced the footprint because the inner packs were no longer having to be stuck to the inside of the cover, making this part essentially ‘two layers’.
They then investigated, sampled and sourced a bespoke thermoformed pulp tray which would hold the tea bags inside the packs and replace the existing 6 board components that made up the inner tray.