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Sleeved cups are f'REAL

F’REAL changes from preprinted to sleeved custom cups for its frozen dairy products.

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When done properly, packaging graphics can perform a distinctive double duty in relieving consumer confusion. Graphics can differentiate products from the competition, and they can also distinguish separate lines within a family of products.

That’s what f’REAL! Foods, Orinda, CA, achieved when it switched from preprinted cups to shrink sleeves for its 10-oz cups of frozen dairy products sold at convenience stores. The 2-mil polyvinyl chloride sleeves, provided by Fort Dearborn, are gravure-printed in nine colors; an adhesive is applied on a 10th station. The sleeves are shrunk around tapered cups, custom-molded of high-impact polystyrene, supplied by Fabri-Kal (www.fabrikal.com). The cups remained unchanged.

There were multiple drivers for the change to sleeves. Says f’REAL director of operations Jens Voges, “We wanted to really differentiate the product lines. We wanted to have much higher-resolution graphics so that we could be more flexible in terms of how the product lines were positioned in the marketplace.

“In addition, in the spring, we released our three-product line of smoothies. We wanted to convey the fact that we had real fruit in a natural product. Printing photographs of real fruit was a huge advantage, something that we couldn’t have done with offset printing.

“Likewise, with the milkshakes, we were looking to position them as old-fashioned, the way real milkshakes are made. We wanted a realistic, silver-metal cup look. Again, that was something that wasn’t possible with offset printing.
“We’ve been pretty successful with these changes.” The format has proven not only successful, but groundbreaking, too, Voges says: “As far as we know, ours is the only full-body, printed shrink sleeve on a frozen product.”

Custom mixer, custom cup

 F’REAL’s products are sold in 2,500 convenience stores, primarily in the Midwest, including Quick Trip, and in the Eastern U.S. at c-stores, including WaWa. Each of the three product lines—milkshakes, frozen cappuccino, and smoothies—offer three flavors. F’REAL also offers a limited-edition seasonal item, Eggnog Milkshake. A tactic that reduced and simplified its investment risk was debuting the sleeves on the limited-edition eggnog in late 2006 (see packworld.com/view-24250).

The products are used in conjunction with a proprietary mixer machine at the c-store. A consumer selects the product, peels off the lid, and positions the product in the mixer. A custom-molded swirl design on the cup bottom locks it into place. “Our cup needed to be tightly integrated with the blender,” Voges points out.

The user chooses a button on the mixer to select the thickness—medium, thicker, or thinner—and pushes the start button. The cup is raised up into the machine, the product is mixed, and the cup with the custom-mixed product is lowered when the cycle is completed. The customer then pays the $1.99 price at checkout.

The cups are provided sleeved by Eastgate Graphics (www.egigroup.com), which used to offset-print the cups. In a joint development with f’REAL, Eastgate selected and installed a new PDC Model R300 sleeve labeler from PDC Intl. and two PDC KST 80”-long steam tunnels to handle the new format.

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