Lipton Advent Calendar

Value engineering / Constructional Design / Visualisation & Sampling

The Brief

Alexir Creative were recently briefed by one of their customers to make palpable changes to an advent calendar format, from the profile design right through to the printing and packing. The original design of the advent calendar had multiple challenges both in the pack format and in the packing. It was a very large profile, had multiple elements and used excess material.

Our Approach

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.

How It Worked

The packing teams now only had to pack the tea bags into the two pulp trays, insert these into the main body of the calendar and seal the packs with a tamper-evident sticker. The simplicity of the erection and packing would dramatically increase the speed on the packing lines and would therefore decrease costs by at least 25%. Also, the design of the new final printed and packed advent calendar reduced board by 65%.