Fonterra were looking to overcome a problem with thermoformed PS pots imploding after being hot-filled, leaving them looking crumpled on shop shelves and unappealing to customers.
Strengthening the pot wall had been ruled out because it would involve non-standard sheet so Chadwicks explored the option of using inverted recess diaphragms (Top Hat foils). Trials showed that these combined well with the pot and provided the sort solution compared to standard aluminium lids.
Chadwicks’ innovative thinking meant the cream tub no longer crumpled during the hot-fill process, made it far more attractive to shoppers and helped trigger a considerable increase in sales.