Corrugated speed tray cuts Little Luko’s assembly time by 65%

Enhancing Little Luko's retail expansion with optimised packaging that cuts both costs and CO2 emissions.

As Little Luko, a premium vertical farm known for its naturally grown microgreens, expanded from direct sales and restaurant supply into major retailers, the need for more efficient and sustainable packaging became clear. A new lightweight, self-erecting tray was developed that assembles 65% faster than the previous design while supporting the brand’s premium image and environmental values.

The Challenge

Little Luko is a vertical farm that combines advanced growing technologies with natural, chemical-free practices. Initially sold online and to restaurants, its premium microgreens are now supplied to major retailers like Makro. To support this expansion, they needed retail packaging better suited to both their product and manual packing process.

The Approach

Our expert team designed a tray optimised for both the primary pack size and production process. The compact design allows two trays to be cut from the same corrugated board, saving materials, reducing waste, and improving warehouse space efficiency. The trays are easy to separate and quick to assemble with their self-erecting base.

The Result

The solution, now called the "speed tray," can be assembled 65% faster than the previous packaging. The new Corrugated Trays uses 56% less material, resulting in significant cost savings for Little Luko. This material reduction, along with an optimised board composition, has saved 4.1 tons of CO₂. The design also won an award at OBAL ROKU 2024, the Czech packaging awards.

See the packing process improvements in action

SUCCESS STORY

Watch how the new “speed tray” solution can be assembled in just 13 seconds, 65% faster than the previous packaging which took 37 seconds to assemble.

Products used by this client

Corrugated Trays

Our portfolio of standard and differentiated corrugated trays are engineered to match your product specifications, supply chain demands, and diverse channel requirements.

View product