Aluminium coffee capsules get a honeycomb packaging solution

In response to evolving coffee roaster needs, secondary-packaging machine manufacturer Cama Group unveiled its latest innovation. As more roasters transition to aluminium capsules, ensuring the integrity of these pods has become a top priority. Cama Group's new honeycomb solution addresses this challenge by providing enhanced protection for aluminium coffee capsules.

Historically, coffee packaging—such as bags, jars, and tins—served a primarily functional role with minimal emphasis on aesthetics. The label was often the sole distinguishing feature, and the process of opening a fresh batch of roasted coffee was straightforward, usually involving nothing more than peeling back a foil lid with a spoon.

However, the landscape of coffee packaging is undergoing a transformation. Today's coffee suppliers are increasingly focused on creating a memorable customer experience, so packaging has become more creative and diverse. According to the team at Cama Group, modern packaging is not just about functionality but also about storytelling and creating a sense of occasion. Their innovative honeycomb solution is a testament to this trend, offering enhanced protection and a touch of sophistication to the coffee experience.

Cama Group Sales Director Alessandro Rocca said, "There are more formats, too. With capsules and pods added to the mix, suppliers are spoilt for choice with what they can achieve with their packaging designs and formats. Customers also have many more variations to choose from."

With the surge in capsule coffee consumption, aluminium capsules have emerged as a recent innovation, replacing the once-dominant plastic versions. Growing concerns over plastic pollution have driven the shift towards aluminium, a more sustainable and recyclable option. While this transition benefits the environment, it has also prompted producers, like coffee roasters, to reconsider their packaging methods.

Rocca said, “Traditional cube boxes are fine for more robust plastic pods, which can jostle into each other during transit with very little to show for it."

“Aluminium, on the other hand, is more susceptible to surface scratches and, as a result, has to be packaged differently to maintain the pristine quality look.”

The design and engineering team at Cama Group sought to develop a solution that would showcase the pods attractively and protect them from dents or damage during transit. Their innovative answer was a honeycomb layout, where the capsules are arranged in a hexagonal pattern and separated by a layer of cardboard, ensuring they remain unblemished throughout transportation.

“Cube containers also deliver smaller surface areas for on-shelf branding, so newer designs are being developed. One is the honeycomb layout, which is where Cama Group is now setting the pace,” Rocca said.

Cama Group was approached by a major South American coffee company seeking a specialised secondary-packaging machine for its aluminium capsules. The challenge involved boxing the capsules in a unique 5-by-2 arrangement while preserving the product's visual quality, a key priority for the coffee roaster.