Cool New Recyclable Ice Cream Packaging for Ben & Jerry’s

Smurfit Westrock works with Ben & Jerry’s to launch recyclable ice cream packaging, advancing sustainability and convenience together.

Ben & Jerry’s challenged Smurfit Westrock to develop a sustainable ice cream packaging solution that eliminated the need for plastic shrink wrap, focusing on durability, recyclability, functionality and visual appeal. Through rapid prototyping and innovative design, a fully recyclable paper-based pack capable of withstanding rigorous performance testing emerged. The final design also featured an integrated handle for easier carrying, enhancing both convenience and consumer experience. This project reinforced Ben & Jerry’s commitment to sustainability and increased brand visibility in the frozen food industry.

The Challenge

Ben & Jerry’s set out to develop a new ice cream packaging solution that eliminated the need for plastic shrink wrap on their two-packs while maintaining package integrity and cooling efficiency under refrigeration and freezing conditions. This challenge would require creating a durable, recyclable and visually distinctive pack that could withstand rigorous performance testing and enhance the consumer experience through both functionality and design.

The Approach

Using rapid prototyping and specialized printing technologies, our structural and graphic design teams worked closely with Ben & Jerry’s parent company, Unilever, to develop a fully recyclable and eye-catching paper-based solution that replaced plastic shrink wrap without compromising strength, functionality or appeal.

After creating and testing several design iterations, our teams settled on a final structure capable of withstanding 200 test cycles with double the product weight.

Additionally, our team went beyond standard ice cream box designs and introduced an integrated handle for easy carrying, improving both convenience and experience for the consumer while reinforcing the brand’s commitment to sustainability.