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CASE STUDY

Cambio: Moulded Fibre Coffee Packaging

Food & BeverageMoulded FibrePackaging
Cambio Roasters coffee range / Source: Zenpack
2 MINUTE READ

Last updated: 12 Dec 2024

Packaging pioneer Zenpack partnered with Cambio Roasters to create moulded pulp packaging for the brand's organic coffee pods. 

THE RESULTS

100%
home compostable
6 months
The time it took for Cambio's customer base to expand to 50 states after launch

THE CHALLENGE

HOW TO MAKE COFFEE POD RECYCLING QUICK, EASY AND EFFICIENT

Coffee pods are a problem, with over 30 million non-recyclable pods heading to landfill every day. Usually a mixture of aluminium and plastic fused together, these pods can't be broken down into their separate materials to be used again, equating to huge resource loss and environmental pollution. Cambio Roasters' new 100% aluminium coffee pods (with a legally required BPA-free food-grade liner) are different, as are its previous polypropylene and aluminium pods. Designed to be simple to recycle thanks to their monomateriality and easy disassembly, the pods were in need of a container to amplify and encourage the brand's recycling ethos. Cambio Roasters partnered with Zenpack to solve this problem, resulting in a Moulded Fibre, stackable and compostable box that doubles up as a recycling bin.

THE SOLUTION

STRUCTURAL INTEGRITY
Cambio Roaster's secondary packaging is made from moulded fibre, a combination of water and paper fibre. To ensure its rigidity, Zenpack added vertical ribs to the design, improving the structural integrity. The container was put through various stacking and fitment tests to determine the optimal wall thickness to keep lids tight during shipping. Each box holds 10 pods and remains useful long after delivery.
GLUE-FREE
To ensure the packaging is 100% recyclable and compostable after use, Zenpack designed a glue-free belly band with tear-strip as a means of visual communication. The cardboard band is printed using a 4-colour lithographic printing process that was optimised to reduce colour shifts. The removal of glue retains the natural integrity of the band and box, meaning both can rejoin nature's circular system.
TRUE CIRCULARITY
The pulp-based container is designed to be used as a temporary, counter-top compost bin, in which users can store their spent coffee grounds when emptying the designed-for-disassembly pods. Once full, the grounds and container can be discarded in the garden or the food waste bin, where they will degrade back into nutrients for the soil.
In 2024, the iF Design Awards recognized Zenpack and Cambio with honors in the Beverages Packaging category.

HOW TO ACTION

1

Find new feedstocks

Most moulded fibre packaging is made with wood pulp sourced from trees. While a renewable resource, trees take time to grow and are essential in our fight against climate change. Look for alternative feedstocks such as miscanthus used by Fibrepac. This highly renewable, perennial crop regrows every year for 30 years and can regenerate degraded soil.

2

Educate on end-of-life

The company advises consumers compost the container. Composting isn't a straightforward practice and can vary dramatically, so a detailed how-to guide would add credibility. Video footage showing how the pack breaks down and in what time frame is also advised.

3

Scrutinise the pulping process

The sulfite chemical pulp process has been the most used pulping process to date, but it has also been shown to cause serious environmental pollution after being released into the environment. The identification of responsible suppliers who use a low number of toxic chemicals is essential.

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