Functionality and aesthetics: the winning combination

The judges were impressed by the carton’s leak-resistant design, ease of use and functionality as well as the novel application of a concept Keypak initially manufactured a few years ago. Now adapted for Castle Lite beer, which emphasises ‘ice cold’ as a core value proposition, the design stood out in its category.

Keypak’s directors, Gary and Jill Jorgensen, express immense pride in winning the overall trophy, attributing the success to their team’s leadership, smart work and dedication. ‘This achievement reflects the collaborative effort of everyone involved, from development to production, who worked tirelessly to bring this vision to life,’ they enthuse. 

The carton’s success lies in its combination of visually appealing design and innovative, consumer-centric features that distinguish it from competitors. 

Gary highlights the collaborative differentiation strategy, which included an advanced leak-proof barrier and specialised hinge system designed to attract consumers and foster brand loyalty. ‘Dave Vermaak of VRV Logistics presented a concept carton that we adapted to work on our production line. We also redefined the locking mechanism and our quality control team played a critical role in ensuring all functionality aspects were executed flawlessly,’ he adds. 

The carton combines sustainably sourced paperboard with an integrated BOPP film layer, creating a leak-proof barrier that maintains integrity when ice is added. Both materials have been tested and confirmed as recyclable, aligning with the growing demand for eco-friendly packaging solutions. 

‘Traditionally, we run solid board through our film laminator. However, this thicker E-flute board required adjustments to the pressure and heating system settings to ensure proper application of the BOPP lamination,’  the production manager notes. 

He goes on to describe the trials conducted to test the BOPP lamination and E-flute board, particularly along the creases and matrix, to prevent damage to the lamination layer. ‘We fine-tuned the pressure on the creases and cutting rules to avoid cut through issues,’ he reports.

The development manager highlights the specialised hinge mechanism, which enhances user experience by enabling easy lid removal and providing a convenient space for adding ice. ‘We needed to ensure the hinge opened wide enough to accommodate ice while maintaining structural rigidity. Achieving this balance required multiple design iterations and rigorous testing,’ he reveals.

He also addresses the challenge of optimising internal space, noting that initial designs featured side flaps that consumed significant capacity, limiting ice addition. ‘We resolved this by meticulously re-engineering the flap design, incorporating additional folds to maximise internal volume without compromising structural integrity,’ he explains.

Gary and Jillian emphasise that overcoming these challenges with innovative design solutions and thorough testing resulted in a carton that seamlessly combines functionality and aesthetics. ‘We are deeply grateful to VRV Logistics for collaborating with us on this project, and to AB InBev for putting their faith in Keypak to produce this carton,’ they state.

The management team is optimistic about leveraging the success of this carton to explore packaging innovations for a broader range of alcoholic beverages, paving the way for sustainable, consumer-focused packaging solutions in the southern African market.