To enhance the consumer experience and boost chocolate sales, our team designed a unique spherical packaging solution that won first place in the inaugural "Huiyuan Printing Cup" Packaging Design Competition at Tianjin University of Science and Technology. In this article, I’ll walk you through the design from five different perspectives.
Structural Design
The spherical chocolate packaging consists of three main components (as shown in Figure 1): two outer boxes and one inner lining. The outer boxes follow a “heaven and earth†box structure, with Box 1 matching the full length of the package. Its front side features a window with a perforated tear line for easy opening. Box 2 is slightly shorter to allow for smooth insertion. The inner lining includes two long flaps, which are attached using double-sided tape to secure the outer box cover. This simple yet functional structure supports mass production and makes the packaging more practical for real-world use.
Figure 1: Spherical Chocolate Packaging Structure
This design’s simplicity not only makes it easy to produce but also ensures that even small structural changes can lead to significant improvements in user experience and market appeal.
Interior Design
For the decorative elements, we drew inspiration from Ferrero's "Golden Classic Golden Romance" theme—simple, elegant, and luxurious. We used ribbons to symbolize the silky texture of chocolate and flowers to represent its sweet flavor. The layout is clean, sophisticated, and visually appealing. As seen in Figure 2, the final design brings together aesthetics and functionality.
Figure 2: Spherical Chocolate Packaging Renderings
Transportation Mode
To make transportation easier, we bonded outer box 2 with the inner lining. One flap of the inner lining was glued to the outer box 2, while the rest remained unattached. The entire unit was then divided into two parts, packed separately, and shipped flat to the manufacturer. This flat design saves space, reduces shipping costs, and makes handling more efficient compared to rigid plastic or metal containers.
Assembly Method
The assembly process is straightforward. First, the bonded inner lining and outer box 2 are molded together. Then, the chocolate is placed inside, followed by the outer box 1. The double-sided tape on the inner lining’s flaps is removed and pushed into box 2, completing the assembly. The height of the flaps matches the outer box, ensuring a secure fit. This method is easy to perform manually, saving both time and labor.
User Experience
Unlike most traditional chocolate packaging, this design uses a push-pull mechanism. When opened, the chocolate emerges from the box; when pushed, it retracts back in. This interactive feature enhances the consumer experience and gives the package a distinctive look. Additionally, the window on the box serves as an anti-theft feature. Since the height of the inner lining matches the chocolate’s height when the box is closed, the package cannot be pulled open before the window is accessed.
As shown in Figure 3, the tearing hole on the window reveals the words “Pull More Exciting.†Following the instructions, gently pulling the box reveals the chocolate in a dramatic way, evoking the feeling of “the sea rising bright moon.â€
Figure 3: Spherical Chocolate Packaging Opening Process
This packaging is ideal for both everyday use and gift-giving. For regular consumers, the push-pull mechanism adds a delightful surprise when opening the package, while the shape after opening makes it easy to share with friends. For gifts, the unexpected design will impress the recipient and reflect the thoughtfulness behind the gift.
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