NatureSweet To Go 2.25 oz + Sam’s/Costco Tripack
As the Packaging Engineer and Graphic Designer, I led the redesign and implementation of the Cherubs To Go line, including the 2.25 oz bowl and the wholesale 3-pack for Sam’s and Costco.
The project focused on converting the original bowl into a fully stackable format, improving transport efficiency, shelf presentation, and overall structural performance—while integrating a licensed PAW Patrol theme across all printed materials.
Brand & Market Alignment
The packaging concept was developed to meet market demand for a kid-friendly, on-the-go tomato solution that reinforced NatureSweet’s brand values of freshness, convenience, and safety.
The updated design integrates a more durable PET bowl and a heat-seal film featuring licensed Paw Patrol artwork, enhancing shelf visibility and consumer appeal.
For club stores, a new 3-pack structure was introduced to improve stackability, transportation efficiency, and overall retail handling.
Structural Concept & Inspiration
The structural approach focused on creating a compact, ergonomic bowl that supports single-serve snacking while maintaining product protection and ventilation.
The bowl’s curved geometry and rib pattern were optimized to strengthen the container, reduce material stress, and maintain clarity around the tomatoes.
For the Sam’s/Costco format, an adhesive wrap-band system allows three units to lock together securely, creating a modular, stackable configuration suitable for high-volume displays and pallet layouts.
Functional Features
Secure Hot-Seal System
As part of the packaging engineering work, I implemented a heat-seal lid system that ensures tamper resistance and product protection throughout transport, while remaining easy to open for consumers.
This sealing method improves freshness retention, reduces dehydration, and prevents accidental opening during handling or shipping.
Optimized Stackability (Redesign Feature)
To support warehouse efficiency for Sam’s Club and Costco, the bowl structure was redesigned with reinforced corners and a tapered geometry that enables stable vertical stacking.
This improvement reduces damage on pallets, increases transport density, and delivers a cleaner presentation in club-store displays.
360° Product Visibility
The transparent PET bowl showcases the cherry tomatoes from all angles, giving shoppers immediate confidence in product freshness and quality.
The clarity of the material also reinforces NatureSweet’s brand promise of transparency and consistent produce standards.
Graphic Design & Labeling
As the graphic and packaging designer on the project, I developed the full visual system for the Paw Patrol–themed Cherubs To Go line. This included:
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A licensed Paw Patrol graphic integration aligned with Paramount/Nickelodeon guidelines
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Playful and vibrant color blocking to enhance shelf visibility for kids and parents
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Clear product communication and updated nutrition/weight information
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A lid layout designed to respect sealing areas and print tolerances
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Print-ready artwork preparation for large-scale flexographic production
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Adaptation of the artwork across individual 2.25 oz units and the 3-pack club format
The result is a packaging solution that balances brand storytelling, licensed character requirements, and manufacturing feasibility—helping the product stand out in both traditional retail and club-store environments.
Labeling Process
For this project, I managed the full labeling workflow for the 2.25 oz Cherubs To Go bowl and the Sam’s/Costco tripack, both of which use a hot-seal label applied directly to the PET lid.
The label was printed on heat-activated PET, selected for its strong bond, flexibility, and ability to maintain color accuracy under refrigerated conditions. I coordinated with suppliers to validate thickness, heat sensitivity, and die-cut tolerances to ensure clean sealing and consistent alignment.
Application was carried out on a Proseal GT1e thermo-sealing unit, where I helped establish optimal temperature, pressure, and dwell-time settings to achieve uniform adhesion without deforming the lid. I also worked with QA to create inspection points for seal integrity, print durability, and label registration through the entire run.
The result was a stable, production-ready hot-seal labeling system that met branding requirements, maintained visual consistency at scale, and integrated seamlessly into NatureSweet’s existing high-speed workflow.
Project Outcomes
The new Cherubs To Go 2.25 oz and Sam’s/Costco tripack achieved stronger shelf presence and improved operational performance. The stackable structure reduced warehouse handling issues, while the refreshed Paw Patrol hot-seal label increased shopper visibility and category engagement.
My Role
I led the full packaging development process, combining structural engineering, material optimization, and graphic adaptation. This included coordinating with thermoforming suppliers, Proseal equipment operators, and label vendors to ensure manufacturability and consistent branding.
Impact & Learnings
This project reinforced the importance of harmonizing engineering constraints with retail aesthetics—designing packaging that protects the product, supports high-volume production, and stands out on shelves.
It also strengthened my cross-functional collaboration skills and my ability to translate brand requirements into functional, scalable packaging solutions.
