In China's Fast-Moving Consumer Goods (FMCG) sector, controlling production costs is a paramount challenge. Nestlé, a global leader in the food and beverage industry, sought to address this challenge through superior product design and innovation to optimize its cost structure and enhance market competitiveness.

To achieve this, Nestlé partnered with LKK Design, renowned for its expertise in industrial design and integrated supply chain management. The collaborative goal was to develop a new gift box for Nestlé's coffee capsules. This project was not merely a packaging upgrade but a deep exploration into merging modern industrial processes with exceptional design.

The client's core requirements were clear and challenging:

• Cost Optimization: Effectively control and reduce production costs without compromising high quality.

• Design Innovation: The packaging design needed to reflect a modern aesthetic and brand value, enhancing the consumer unboxing experience.

• Manufacturing Feasibility: The design had to be viable for large-scale industrial production, ensuring efficiency and reliability.

• Rapid Market Launch: A seamless, one-stop solution from design to manufacturing was essential to ensure a swift time-to-market.

LKK Design leveraged its unique integrated "Design + Supply Chain Management" service model to provide end-to-end support for this project.

1. Design Research
Our team began with in-depth research into market trends, competitor packaging, and consumer usage habits. We concurrently analyzed the AIO (All-In-One) process in packaging production, precisely identifying key links affecting cost and efficiency. This provided a solid data foundation for all subsequent design decisions.

2. Industrial Design
In the industrial design phase, we focused on the gift box's structure and user experience. Particular attention was paid to the flip-top lid, where we engineered a meticulous design to ensure smooth operation, durability, and an optimal presentation of the coffee capsules inside.

3. Mechanical Structure Design
This was the core phase for achieving cost reduction and efficiency gains. For the labeling/bonding process of the flip-top section, LKK Design's engineering team did not propose a single solution. Instead, we innovatively simulated and presented three distinct production processes for the client to choose from:

• In-Mold Injection

• Ultrasonic Welding

• In-Film Lamination

For each process, we prepared detailed technical explanations, cost analyses, and illustrated reports, clearly outlining the pros and cons of each option in terms of production efficiency, cost control, and final quality. This empowered the client to make the best strategic decision.

4. Prototyping and Testing
Once the solution was finalized, we created physical prototypes through rapid prototyping. These underwent rigorous functional testing and assembly validation to ensure every design detail could be perfectly realized in mass production, thereby avoiding costly modifications at later stages.

The collaboration between Nestlé and LKK Design yielded significant success:

• Successful Product Launch: The tailor-made Nestlé Capsule Coffee Gift Box was successfully mass-produced and launched, now available to consumers through online channels.

• Breakthrough in Cost Efficiency: By offering innovative design and multiple manufacturing options, we directly addressed the central cost pain point in the FMCG industry, achieving the client's goal of reducing costs and increasing efficiency.

• One-Stop Innovation: This project perfectly exemplifies LKK Design's one-stop service capability—from product strategy and industrial design to supply chain management—ensuring a highly efficient and high-quality transition from "concept" to "market-ready product."