PPI’s PIDA Nominate Coffee Trays – changing and safeguarding the way of takeaway coffee 

Coffee has kept up with the changing lifestyle and commuter culture which demanded and (therefore) led to the invention of cardboard coffee holder trays. They provided a convenient, lightweight and disposable solution to enjoy food and beverages on the go.  

However, the current design is known to cause topples, spillages and burns to the person holding it.  

PPI wanted to approach the aspects of sturdiness and safety that were missing from the conventional model available in the market. Therefore, using our design expertise and experience – we set out to create a new and better takeaway coffee tray.  

The Problem 

Takeaway coffee trays currently available in the market are crafted using board material. This type of material comprises recycled content and prioritises sustainability above all. However, board material doesn’t offer great mechanical strength. This underscores the structural integrity of conventional takeaway coffee trays, especially with the added weight of coffee cups.  

The Solution 

We crafted a more reliable solution to what is commonly used with added benefits, such as: 

• Engineered for strong structural integrity 

• Enhanced sturdiness and reliability 

• Convenient for carrying up to 4 cups 

• Quick and straightforward to assemble  

• Simple manufacturing process 

• Minimal material usage 

• Suitable for various F&B establishments, including catering 

• Reduces spills and burns 

Design and Innovation 

To achieve an elevated and more reliable version of the existing design, we incorporated both design and material efficiencies. 

PPI’s tray features 45-degree creases at each of the four corners, which create two vertical walls between the top and bottom panels. This helps maintain the flatness of the top panel, despite any added weight of the drink cups. It also reinforces the overall structure of the tray. 

Slots have been added to the design to securely fit the vertical panels and tabs. This ensures the assembled trays are stable and reliable throughout their use. 

The angled creases help facilitate swift and effortless assembly of the coffee tray. While the cup-gripping cuts ensure there is sufficient friction to securely hold cups of any size. 

The star feature of this design is the innovative folding, that creates within the structure – two handles (one on each side). This allows security and efficiency in handling hot drinks, for both serves and customers alike. 

The manufacturing process for our trays involves die-cutting and straight-line gluing, which simplifies the production. The production for this tray can be streamlined, making it faster and more straightforward than other trays available in the market.  

These trays can be stored and transported flat, we strategically incorporated this in the design to minimise the storage space requirements and enhance efficiency during transportation. Thus, also reducing their shipping cost. 

“The design I focused on was about improving the takeaway coffee tray, particularly when carrying four large, full coffee cups, to address concerns about spills and burns. Given the high volume of production and consumption, enhancing the quality of the material wasn’t feasible. Instead, I focused on developing an innovative structure that includes 45-degree creases for enhanced sturdiness, secure cup-gripping cuts, and built-in handles for better handling. These features work together to provide a safer and more reliable experience for both servers and customers, while also minimising environmental impact through efficient material use, production and storage.”  

– Azadeh Yousefi, Industrial Packaging Designer – PPI 

Sustainability Consideration 

Our trays embody the principles of sustainability at every stage of its lifecycle.  

Crafted from 100% recycled boards, assembled using starch-based adhesives and can be printed with water-soluble, non-toxic inks. The environmental impact of these trays is minimal. 

We optimise the material usage to minimise wastage while ensuring all resources are used efficiently during production. 

Additionally, the flat storage of the trays lowers the overall carbon footprint associated with their transport. 

Our holistic approach is based on sustainability-first, evident in every aspect of our design. We are dedicated to providing sustainable packaging solutions, which are practical for businesses and customers alike. 

PPI’s takeaway coffee tray received the Silver Award at the Australian Packaging Innovation and Design Awards (PIDA) in 2024.