IN A NUTSHELL

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How might we redesign ready meal packaging to create a circular product service system?

Nutshell’s aim is to redesign a system for a ready meal packaging where energy consumption, carbon footprint, and impact on the environment are significantly reduced. Nutshell plans to do this by extending the life of ready meal packaging and to minimise the end of life impact to the environment whilst providing a healthy, instagramble food product.

did you know?

19kg (on average) of ready meal packaging waste per person per year is going to landfill.

The UK is expected to run out of landfill space in less than 8 years.

The UK is the fattest country in Europe and spends £4.7 billion each year on ready meals

where nutshell fits in...

Nutshell’s packaging uses waste eggshell and nutshell, so even before its development into the packaging, it is reducing waste going to landfill.

Nutshell’s online ordering system allows for targeted healthy meals for weight loss/gain specific to each user.

Nutshell reuses ready meal packaging meaning it doesn't just provide for one person's meal it provides for many.

When the packaging has eventually reached its end of life it is composted and used to grow nuts that are used in new packaging.

how it works

The shells are cleaned:
The eggshells are centrifuged to remove residue and then both egg and nut shells are washed and grinded ready for use.

Sourcing Egg and Nutshells:
Both are collected for free from UK nut and egg manufacturers

Food Production: 
We fill each pot with healthy food that is made to specific user preferences and weight goals. Food waste from production goes to compost.

Deliveries:
The consumer has 2 options when ordering, 7 meals or 14 meals. This is dinner or dinner and lunch for the entire week. The deliveries are carried out by electric vans and routes arround London are optimised to find the shortest route. 

Composting:

If the pot/ box/ tray can no longer be reused, it is composted in an aerated static pile. The compost is used to help boil water in the manufacturing process and grow pistachio nuts. These nuts are then sold and the shells used for manufacture 

Box  drop and collection:
There will be specific windows for drop and collection. As new pots are delivered, the user is expected to put out the old box filled with used pots to be taken back to our factories to be cleaned. If they don’t give back the box they will be charged for it.

Pre Compost checks:

If the boxes, pots or trays fail any of the quality checks they will be composted. However, they must be checked for metals before going into the pile as this could be hazardous

Biodegradable polymer production: 
Using egg and nutshells a fully biodegradable polymer is manufactured, using heat from the compost heap to help with the process.

Manufacturing process: 
The polymer is injection moulded into nut shaped boxes, trays and flower-inspired pots. The pots and boxes are laser-etched with a bar code so they can be tracked through the process.

User discovers or returns to Nutshell:
Users discover Nutshell through social media advertisements. They visit our website or app to input /update data, allowing us to find the best plan for them to achieve their weight loss/ weight gain goals. The user pays online. The user will be able to track their weight plan online via our website/app.

The shells are cleaned:
The eggshells are centrifuged to remove residue and then both egg and nut shells are washed and grinded ready for use.

Sourcing Egg and Nutshells:
Both are collected for free from UK nut and egg manufacturers

Composting:

If the pot/ box/ tray can no longer be reused, it is composted in an aerated static pile. The compost is used to help boil water in the manufacturing process and grow pistachio nuts. These nuts are then sold and the shells used for manufacture 

Pre Compost checks:

If the boxes, pots or trays fail any of the quality checks they will be composted. However, they must be checked for metals before going into the pile as this could be hazardous

Food Production: 
We fill each pot with healthy food that is made to specific user preferences and weight goals. Food waste from production goes to compost.

Deliveries:
The consumer has 2 options when ordering, 7 meals or 14 meals. This is dinner or dinner and lunch for the entire week. The deliveries are carried out by electric vans and routes arround London are optimised to find the shortest route. 

Rewards: 
When the users return pots they get money off their next week’s food.  Also by sharing a photo of thier pot and progress on social media, they also recive money off thier next meal plan.

Box  drop and collection:
There will be specific windows for drop and collection. As new pots are delivered, the user is expected to put out the old box filled with used pots to be taken back to our factories to be cleaned. If they don’t give back the box they will be charged for it.

Quality checks:
The pots undergo three quality check. The boxes and trays only go through the first process.

Cleaning process
The used boxes and trays get washed with antibacterial detergent, but the parts of the pots that touch food go through a super wash system which cleans right down to a microbial level.

Reuse:
Once the pots/boxes/trays are clean they are put back into the orignal system for reuse. 

In a Nutshell utilises a completely circular product-service system that is environmentally friendly. The system is both convenient and adds a new twist to the ready meal market. (Full details on desktop version)

my role

In this project, I contributed heavily to the circular product system formulation and was solely responsible for the product and branding concept.

As a requirement of the project, we had to produce a video detailing the proposed product-service system solution. This animated video was solely produced by me and can be seen below: