Development of Next-Generation Packaging: The Tray Paper Pack

Achieving a 100% recycling rate for containers and packaging is considered essential for establishing a recycling-oriented society. Our company aims to accomplish this goal by 2050 and launched the Eco-Friendly Project in January 2023 to develop next-generation packaging solutions. This project explores the feasibility of large-scale adoption of environmentally friendly packaging through small-scale test sales. As part of the project, we developed and tested four products for household use and two for commercial use.

In the fourth trial of the project, we introduced the ‘Tray Paper Pack’, an eco-friendly packaging solution used for limited-quantity beverage sales on a commercial e-commerce platform in Japan. A key feature of this pack is its use of micro-flute corrugated cardboard and exterior packaging paper, significantly reducing material consumption. The outer packaging paper incorporates 70% recycled material, replacing virgin pulp to enhance sustainability.

Furthermore, when designing the ‘Tray Paper Pack,’ we referenced secondary toilet paper packaging and modified the structure to withstand the heavy weight of canned products.

To verify its suitability for e-commerce distribution, we conducted three evaluation tests. Firstly, a home delivery test confirmed that the tray, made of two layers of micro-flute cardboard, provided sufficient durability during shipping. Secondly, a water resistance test evaluated the pack’s ability to withstand exposure to rain during home delivery.

 The results showed that the packaging maintained its structural integrity and prevented the cans from scattering when subjected to simulated rain conditions. Thirdly, small-scale production was carried out to identify potential manufacturing challenges. This revealed that the original design caused damage to the outer packaging paper during production, leading us to refine both the outer packaging and tray structure. Based on these evaluation results, we determined that the ‘Tray Paper Pack’ is suitable for commercial distribution in the e-commerce market. Additionally, compared to conventional packaging, this pack reduces total paper usage by approximately 21% and carbon dioxide emissions by approximately 28%, contributing to a more sustainable packaging solution.