Customer Stories
Innovative, Sustainable, and Cost-Effective Packaging for Germicidal V…
The Challenge
Redesigning the Banana Split Experience
For decades, Culver’s relied on a stock container to serve its banana split. This container, however, had a significant flaw—it was held together by two light snaps that often failed to keep the package closed. Customers frequently experienced spills when handling the dessert, and once the custard began to melt, leakage became an unavoidable issue. Culver’s needed a packaging solution that would maintain the integrity of the dessert, prevent leakage, and enhance customer experience.
The Process
Engineering a Better Banana Split
Understanding the core issues, Culver’s partnered with Plastic Ingenuity to design a new, custom package. The goal was to eliminate spillage, improve the container’s durability, and maintain cost efficiency using recyclable materials. Plastic Ingenuity approached the challenge by creating a larger, more secure container while retaining a single-part design.
The key advancement was the introduction of a full-perimeter snap, ensuring the package remained securely closed even when handled. The new design also allowed for a broader banana range and more toppings without compromising stability. Further refinements included a fluted structure, or high beams, which prevented the container from crushing under pressure. Additionally, Culver’s logo was engraved on the top of the container to enhance brand identity.
To maintain food safety and meet biological and chemical requirements, the package was manufactured using FDA-approved PET, a fully recyclable material. Rigorous testing ensured the container remained leak-resistant and securely closed under real-world conditions. The success of these tests confirmed that the new package would provide an optimal solution.
The Solution
Enhancing Efficiency, Sustainability, and Customer Experience
The final design met Culver’s requirements, offering superior protection and ease of use. The package features two identical interlocking parts, simplifying employee loading and eliminating confusion. Additionally, the flute structure allowed Plastic Ingenuity to use a lighter, more cost-effective .015-gauge material without compromising durability.
The new package transformed the banana split experience for Culver’s customers. Guests could now enjoy their dessert without the fear of spills or leaks. Employees found the redesigned package easy to assemble and store, increasing operational efficiency.
The packaging’s lightweight yet durable construction meant Culver’s could maintain an affordable solution while improving customer satisfaction. Additionally, environmental considerations were incorporated into the design. The fully recyclable PET material aligns with Culver’s sustainability goals, and the uniform top and bottom structure reduces waste by limiting the need for unnecessary lids when serving dine-in customers.
The Results
A Resounding Success
%
100% recyclable
Lightweight .015 gauge PET material
x
Increased guest satisfaction
