GreenBrew Coffee is a Manchester-based subscription service delivering single-origin and small-batch roasts to coffee aficionados across the UK. Founded by siblings Jade and Rowan Smith, the company prides itself on ethical sourcing, fresh flavours, and a personalized tasting experience that has inspired a devoted following of craft-coffee enthusiasts.
Not Just a Box
As GreenBrew’s subscriber base grew, its packaging began to show serious flaws. Standard kraft mailers offered little internal support, causing up to 35 percent of coffee bags to shift and crease in transit. Without a resealable closure, beans lost freshness quickly, disappointing customers. Oversized secondary cartons compounded the problem by inflating freight charges by nearly 25 percent and stretching delivery timelines, threatening subscription renewals.
Where We Came In
Aly Packaging UK started with an in-depth consultation to understand GreenBrew’s dimensions, branding goals, and delivery feedback. After reviewing customer comments on freshness and unboxing, our design team proposed a dual-chamber box to cradle a resealable coffee pouch alongside a branded insert. Within 48 hours, we provided a precision die-line and 3D mockup reflecting GreenBrew’s clean aesthetic. Our ink specialists then calibrated food-grade soy inks to render rich, earthy tones on uncoated kraft board, and our production floor delivered a 500-unit pilot run in just 12 business days.
The Right Fit
The final design featured a snug inner sleeve that stabilized each pouch, a pull-tab closure to preserve aroma, and a natural kraft finish that echoed GreenBrew’s commitment to authenticity. Subtle embossing of the company emblem added a tactile touch, and the streamlined form factor reduced package weight by 18 percent compared to the previous solution.
What Changed
Following the launch, GreenBrew saw a 35 percent drop in transit damage and a 22 percent reduction in shipping costs thanks to the lighter, form-fitting design. Subscriber renewals rose by 15 percent as fresher beans and a premium unboxing experience boosted customer satisfaction. The faster production turnaround also enabled GreenBrew to introduce seasonal edition boxes two weeks ahead of schedule.
Client Testimonial
“Aly Packaging UK transformed our delivery process,” says Jade Smith, Co-Founder of GreenBrew Coffee. “Our subscribers now receive beans that taste as fresh as the day they were roasted, and we’ve cut shipping costs at the same time.”
Company Commentary
“Great packaging must honor both product and brand values,” explains Ali Ahmed, Lead Packaging Advisor at Aly Packaging UK. “By creating a dual-chamber design and focusing on weight reduction, we helped GreenBrew exceed their operational and customer experience goals.”
Ready to Brew Success?
Whether you’re launching a subscription service or scaling your retail operations, Aly Packaging UK offers tailored, sustainable packaging solutions that protect your product and delight your customers. Contact us today for a free consultation and sample pack.
