Adidas' retro-inspired aluminum can design reduces material weight
Trivium Packaging, headquartered in Amsterdam, Netherlands, with operations in São Paulo, Brazil, developed a redesigned aluminum can for Adidas. Produced by the company’s Brazilian division, the can was created to balance a retro-inspired visual style with a refined surface finish while maintaining clear presentation of essential product information. The design incorporates a background pattern of small dots to create a sense of depth and texture, while a specialized ink formulation allows metallic colors to blend smoothly without visible inconsistencies across the surface. Beyond its visual characteristics, the project focuses heavily on material efficiency and manufacturing improvements. Trivium Packaging standardized and optimized the can format used in production, enabling a reduction in total weight of approximately 25%. The company achieved this by utilizing a more advanced aluminum alloy combined with a production process that eliminates conventional bar fusion, which typically requires additional energy and material inputs. According to the company, these technical changes contribute to a reduction of more than 50% in carbon dioxide emissions during production while maintaining the structural integrity and performance required for beverage packaging. The internal coating applied to the can was also reduced by 50%, decreasing the amount of coating material required and lowering associated volatile organic compound (VOC) and CO₂ emissions. The result is a lightweight aluminum packaging format that integrates design features with modifications to materials, coatings, and manufacturing processes in order to reduce environmental impacts while preserving durability and product protection.
The initiative focuses on optimizing material usage through adjustments such as reducing overall plastic grammage, refining bottle wall thickness, and improving cap and closure efficiency.ThePackHub
Himalaya Wellness Company lightweights baby care packaging to reduce plastic
Himalaya Wellness Company, headquartered in Bengaluru, India, has implemented a packaging redesign across its Gentle Baby Care range aimed at reducing plastic consumption by approximately 500 tons over a five-year period. The initiative focuses on optimizing material usage through adjustments such as reducing overall plastic grammage, refining bottle wall thickness, and improving cap and closure efficiency while maintaining structural integrity and compliance with safety standards required for baby care products. In certain units, secondary packaging has also been eliminated where deemed non-essential. The redesign process involved cross-functional collaboration between research and development, packaging engineering, quality assurance, and regulatory teams, with extensive testing including compatibility studies, transit simulations, and stability assessments to ensure product safety and hygiene are not compromised. The initiative has been implemented across the full product portfolio nationwide, embedding material reduction into standardized manufacturing specifications and monitored through defined key performance indicators.
The company reports that the revised packaging format reduces paper usage by approximately 25%.ThePackHub
Kellanova's carton redesign reduces paper use in snack multipack packaging
Kellanova has redesigned the packaging used for its LCMs Treatz snack range to reduce paper consumption across its supply chain. The company reports that the revised packaging format reduces paper usage by approximately 25%, resulting in an estimated saving of 34.2 tons of paper compared with packaging volumes used in 2024. The update follows a review of the existing retail packs and shelf-ready display units, during which the company identified opportunities to optimize the size and structure of the packaging while keeping the product formulation and weight unchanged. As part of the redesign, the outer carton has been reduced in size, resulting in a more compact format that uses less paperboard material. In addition, the shelf-ready packaging has been modified to a single-facing case format, allowing the product to be displayed efficiently on retail shelves while reducing overall material use. The structural adjustments are intended to remove excess space within the packaging system while maintaining the functional requirements for retail presentation, transport, and product protection. To ensure consumers understand that the product quantity remains unchanged, the new packaging includes an on-pack message stating: “Same weight, 25% less packaging compared with previous LCMs Treatz pack.” The updated packaging is currently being rolled out nationally, accompanied by digital, in-store, and print communications intended to inform consumers about the material reduction.
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