The Challenge

Caroline’s Cakes’ brand potential was being limited by its packaging.

Their team received consistent feedback from customers disappointed to see the cakes arrive in expanded polystyrene foam cooler (EPS, often known as Styrofoam®) and frustrated with the burden of disposing it. To address those concerns, meet the heightened expectations of fans around the country, and live up to their own values, the Caroline’s Cakes team looked to re-design their pack-out with better materials.

- Customer Quote -

Working with the TemperPack team has exceeded expectations at every opportunity. They approached our issue with care and concern for us as a customer and were active participants in troubleshooting our packaging wants and needs. Their hard work and attention to detail has helped us to transition to completely recyclable packaging without any disruption in our day-to-day operations. I value the relationship we have built and look forward to the next project that I can work on with their team.

Richard R. Reutter

President & CEO, Caroline’s Cakes

The Challenge

Caroline’s Cakes’ brand potential was being limited by its packaging.

Their team received consistent feedback from customers disappointed to see the cakes arrive in expanded polystyrene foam cooler (EPS, often known as Styrofoam®) and frustrated with the burden of disposing it. To address those concerns, meet the heightened expectations of fans around the country, and live up to their own values, the Caroline’s Cakes team looked to re-design their pack-out with better materials.

- Customer Quote -

Working with the TemperPack team has exceeded expectations at every opportunity. They approached our issue with care and concern for us as a customer and were active participants in troubleshooting our packaging wants and needs. Their hard work and attention to detail has helped us to transition to completely recyclable packaging without any disruption in our day-to-day operations. I value the relationship we have built and look forward to the next project that I can work on with their team.

Richard R. Reutter

President & CEO, Caroline’s Cakes

The Process

Discovery

Understanding Caroline Cake’s requirements, including fulfillment process, payload specs, shipping lanes, optimal temperature, and more.

Design

Developing pack-out designs to meet those needs. For Caroline’s Cakes, the engineers had to consider a few specific criteria:

Design Criteria

Summer Heat

Caroline’s Cakes ships out of its Spartanburg, SC facility and has a large base of fans in the South. The shipper design had to stand up to summer conditions beyond ISTA-7E.

Air Flow in the Shipper

To protect the bottom of the cake and maintain consistent temperature throughout the box, TemperPack designed a corrugated tray to elevate the cake tin and create space for airflow.

Multiple Sizes & Payloads

The TemperPack team designed four shippers for various cakes, cake bites, BBQ, and seasonal items.

Design Criteria

Summer Heat

Caroline’s Cakes ships out of its Spartanburg, SC facility and has a large base of fans in the South. The shipper design had to stand up to summer conditions beyond ISTA-7E.

Air Flow in the Shipper

To protect the bottom of the cake and maintain consistent temperature throughout the box, TemperPack designed a corrugated tray to elevate the cake tin and create space for airflow.

Multiple Sizes & Payloads

The TemperPack team designed four shippers for various cakes, cake bites, BBQ, and seasonal items.

Qualification

Testing multiple samples of every design against Caroline’s preferred ambient profile, to ensure shippers would maintain frozen temperature during the summer.

The Results

Customer Review, October 2023

"5 Stars - Thanks for the great product, and the careful packaging and shipping!"

Customer Review, December 2023

"The care and attention to detail in packaging are as impressive as the cake! Thank you!"

100,000

LBS of EPS

By switching from EPS to ClimaCell, Caroline’s Cakes will help keep 100,000 pounds of EPS from going into landfills each year, a win for cake fans everywhere.