AICC Corrugate Competition

Our team designed a single wall E-flute roll over tray box with a separate, single wall E-flute insert. Our package design was made to be cost-effective by making our box as small and as light as possible, avoiding the use of glue and glue flaps, and having a separate insert to hold the items securely. The package also meets the requirements of a shipper including its size, weight, and having no text on the top of the box. Our final submission also includes windows for the glasses and a protective flap that resemble the shape of the hole signs found at Whistling Straits, the next Ryder Cup location.
Early on our structural design focused on the placement of the objects within the box and how to display them so that the items were presented to the consumer in a pleasing way while still keeping them protected and as compact as possible. We met with biweekly discussions via video conference and had a few in-person socially distant meetings as well. The structural team each worked separately, reworking the layout of the items and using elements of each other’s designs. Throughout that process, we experimented with design concepts like accordion folds, tab locks, and even tongue flaps for the glasses.
Our final insert design has two roll-in flaps used to hold those glasses, so they are unable to roll around and break. They neatly hold the other items in between them as well. We had two successful designs where the insert was either separate from the exterior box or as one piece altogether. The decision was made near the end of the design’s construction to opt for two separate pieces. This made it easier to fold and place the items into the box. Our final submission is a box that is a single-wall, E-flute, friction-fit, rollover tray, and includes a separate insert made from single-wall, E-flute.