Jingle Balls
2023A family of sustainable packaging for christmas ornaments
Kaemingk asked FLEX/design to replace plastic-heavy ornament packaging with a paper-based system without losing the clear, shop-stopping visibility that sells baubles. We treated the pilot as a fast tryout before a full launch the following year.Brief
Garden centres and DIY chains such as Praxis rely on quick merchandising and strong shelf read. The mandate was precise: remove plastic where possible, keep the ornaments highly visible and beautifully presented, hold dimensions close to the legacy packs so the same number of boxes still fits a pallet, and move fast.
Range
The pilot covered seven SKUs, from small single-diameter sets to larger assortments, plus a mixed “hero” box. It needed a single visual language that could stretch from value to giftable without fragmenting the shelf.
Approach
We set visibility as the north star and built structure around it. If the product is the billboard, the board should frame rather than hide it. We mapped a wide idea space in the first two weeks so the client could choose a direction quickly and still keep options open as we learned.
Exploration
We produced roughly fifteen distinct concept directions, including bavatex sleeves, netted displays, bold cutouts, and other more experimental containers. Each explored a different trade-off between openness, durability, handling, and yield. The process was deliberately hands-on: we mocked, cut, folded, and stress-tested with real ornaments to see what failed early.
Two architectures that won
Sandwich for glass
Two flat boards capture the baubles at the poles with tuned spacers that spread shock and stop rattle, while large apertures keep most of each ornament visible. The structure removes point loads, keeps finishes clean, and presents the set as a calm, premium grid.
Hexagonal box for shatterproof plastic
A six-panel tube with faceted windows creates a strong, self-bracing shell. Internal keys lock each bauble’s orientation so the hero finishes stay facing forward during shipping and restocking. The hexagon reads sculptural on shelf and nests cleanly in trays.
Materials and finish
We chose black corrugated board for instant contrast against the ornaments, which instantly provides the premium feel we were aiming for.
Prototyping and pace
The project ran from March to June. In the first fortnight we moved from sketches to cut-plotter prototypes, using simple jigs to test window edges, anti-scuff dividers, and rotation locks. By week four we had dimensionally locked dielines aligned to existing pallet footprints. In June, the Kaemingk team reviewed the concepts with suppliers in China to validate manufacturability and line changeovers.
Outcome
The tryout did what it needed to do: it proved that paper-based packs can deliver premium visibility, stable transit, and fast shelf work without blowing up cost or logistics. On the back of that success, the range expanded significantly the following season, and a bigger variety of products will be available in the 2025 season.