Forever Roll Packaging

Forever Roll Packaging was one of four internship projects I completed in Innovation Design for P&G. I designed for Bounty and Charmin products currently in the market.

Existing Charmin Forever Roll Starter Kit

Existing Bounty Forever Roll Starter Kit

The Forever Roll is a very high-quantity sheet-per-roll product made by P&G for the Bounty and Charmin brands. The Forever Roll can be used much longer than regular rolls.

In my new design, I addressed 3 issues:

Opening
Break Down
Storage for Extra Roll

Opening

“The box is really hard to open. I hate having to pry it open with my fingers.”

By investigating this common problem, I identified opportunities for opening the box:

Opening the boxes should be pain free.
Once open, the boxes should be able to close without using outside materials or force.

I looked at examples of other boxes. Large tabs on top helped to make the boxes easier to open and gave them the ability to close.

I didn’t want to interfere with the existing box’s window. The tab openings were on the top back side.

Break Down

“The box is hard to flatten for recycling.”

Since the box would already be opened from the top, I needed to address construction at the bottom of the box to ease the break down process.

After meetings with the Packaging Engineer, he recommended I investigate collapsible carton boxes. I prototyped scale models and adapted the dielines in Illustrator for the 2 different boxes.

Extra Roll Storage

I was also tasked to address what consumers would do with the big boxes after setting up the first half of the starter kits. The boxes were quite large to keep in storage.

Since the 2 Charmin rolls are double wrapped, I designed a smaller lightweight box that would be taken out from inside and used as storage for the extra roll.

The Bounty version was larger and rectangular, which prompted a different solution. The second roll could come with a wrap to ensure that it would remain clean while in storage.

Final Scale Models

Takeaways

Setting Objectives

I learned how to articulate the 3 design objectives (opening, breakdown, and storage) to clarify this project’s outcomes and deliverables.

Packaging Dielines in Illustrator

After researching outside designs for functionality, I adapted the dielines in Adobe Illustrator to prototype a functioning scale model.