Packaging Design & Development
A Case Study

How AVA developed technically challenging retort packaging for Masterfoods Cocoa Via nutritional drinks.

Masterfoods - Packaging Design & Development

AVA packaging solutions developed technically challenging retort packaging for Masterfoods Cocoa Via nutritional drinks.


  • AVA developed a range of 3D CAD designs, visualisations and dimensionally accurate rapid prototypes – introducing a new technology to Masterfoods.
      

  • AVA project managed the whole development, coordinating the UK current and trial manufacturing base and the Polish Greenfield manufacturing bases and Masterfoods internal teams.

  • AVA developed a new bottle for a premium health and milk based drink to be consumer preferred to current bottles, maintain the consumer aesthetics of the current bottle and designed for retort.

  • AVA developed a range of 3 bottle necks, foils and closures and selected one to have a consumer preferred 'mouth' feel optimised for thermal sealing.  The technology of bottle manufacture was prescribed – lost head blow moulding.

  • Bottles to be suitable for neck handling during rotary filling and sealing and demonstrated that the seal integrity exceeded client AQL of 100ppm defective.  We ensured that both Fo and CP retention targets are achieved in the new bottle.

  • Bottles delivered against tight cost constraints.

  • AVA developed a superior bottle for retort, proven through trials and testing to deliver technically superior bottle v stringent technical and quality constraints and proven through consumer research to deliver superior bottle in terms of aesthetics, mouth feel and ergonomics, of closure, foil and bottle.