Project Overview

deliverables

• Maintain frozen temperature of soups for 2 days during transit.

• Prevent condensation from affecting other products.

• Create a compact, cost-efficient shipper

• Ensure stacking strength, transit durability and efficient fulfillment assembly.

solution

Structural

• Created a tiered corrugate configuration.

• The bottom layer consisting of the sweets and sides boxes placed side by side.

• The soup box as the top layer reinforcing load distribution.

• Optimized footprint to reduce void space and dimensional weight.

Thermal strategy and testing

• Enclosed the soups in an insulated mailer.

• Optimized the quantity and placement of gel packs.

• Conducted iterative 48 hour transit simulation.

• Selected insulation that consistently maintained the frozen state.

outcome and impact

• Successfully achieved the 48-hour frozen compliance.

• No condensation damage to the ambient products.

• Structurally validated for transit.

• Enabled scalable bundled project launch.

FROZEN + AMBIENT MULTIPACK BOX/SHIPPER

This case study showcases a corrugated shipping solution for a bundled food set containing frozen soups, cookies, and a side dish. The design uses individual primary cartons for each item, all packed into a single master shipper. The key challenge was maintaining soup in a fully frozen state for 48 hours while preventing moisture exposure and damage to ambient products. The final structure balances thermal protection, cushioning, and efficient packing for safe, consolidated delivery.