Introduction

Sear & Serve, a fast-growing brand specializing in premium-quality sous vide cooked meals, faced a crucial challenge. They needed to launch a brand-new product line across traditional and club retail stores. With no prior design in place, they required an elevated, sophisticated packaging solution that would stand out on crowded shelves and justify a premium price point.

With a tight timeline of four months to launch, Sear & Serve approached MOUZ Design for a comprehensive design overhaul. The goal? To develop distinctive packaging that would attract customers, reflect the brand’s premium positioning, and meet stringent industry regulations.

Objective & Goals

Key Goal: Launch a fully developed product line with distinctive, premium packaging across retail stores within a four-month timeline.

To achieve this, we focused on three main objectives:

1. Design a visually striking, premium look that would grab attention on retail shelves.
2. Develop versatile packaging formats that fit production capabilities and consumer preferences.
3. Ensure regulatory compliance by securing USDA approval for the final packaging design.

The Process

Our process was systematic, collaborative, and focused on delivering results at every stage. From concept development to final production, we ensured that each step aligned with Sear & Serve’s brand vision and timeline.

1. Packaging Format Development

We collaborated closely with production managers and printing vendors to develop versatile, cost-effective packaging formats that would meet both production requirements and consumer preferences. The final format included two types of sleeves and one box.

Challenges and Solutions:

• Material Selection: We needed a paper/cardboard material that would maintain a premium look in both freezer and fridge conditions while remaining cost-effective. After several rounds of testing, we identified a material that preserved the premium aesthetic without sacrificing functionality.
• Production Feasibility: Ensuring compatibility with the production line was essential. We worked with production managers to ensure the formats could be produced without costly changes to manufacturing processes.

2. Package Design Development

Research & Insights:

• Market Analysis: We conducted in-depth research on top-selling competitors and analyzed failed products to understand what works and what doesn’t.
• On-Site Analysis: We visited grocery stores to study how competitor products were displayed on shelves. This on-the-ground research provided insights into layout, shelf presence, and how certain design elements caught customers’ attention.

Concept Development:

• Initial Concepts: We presented two unique design concepts to Sear & Serve, each built around a different emotional driver:
  • Sustainability & Health — A clean, fresh, eco-conscious look.
  • Indulgence & Premium Feel — A bold, rich, and luxurious presentation.

Design Drafting:

• To give the client a clear vision of the end product, we used AI-generated images to create early-stage design mockups. This allowed the client to visualize the final design before we moved to more time-intensive production tasks like photography and printing.

Photoshoot:

• We arranged a full-scale photoshoot to capture key images for the package, sales applications, and media use. This shoot produced a range of visuals, from hero shots for the packaging to clean product shots for the client’s internal marketing purposes.

Final Design Execution:

• After multiple rounds of client feedback and refinement, we finalized the design, ensuring it reflected the brand’s premium positioning while also maintaining visual clarity on the shelf.
• The packaging design incorporated a sophisticated, modern layout with a bold visual hierarchy. Clean typography ensured readability, while strategic use of high-quality imagery and subtle textures conveyed a sense of indulgence and quality. The design balanced aesthetic appeal with functional clarity, aligning perfectly with the brand’s premium market positioning.
• 3D Renders for Sales: We created realistic 3D renders of the final package to support the sales team’s buyer presentations. These renders were critical for early buyer engagement and helped secure retail support even before physical production began.

3. Compliance & Production

USDA Approval:

• The USDA has strict requirements for food packaging, including content layout, font sizes, claim language, and callout styles. We handled the entire USDA submission process, working with Sear & Serve’s internal regulatory team to ensure the design met all requirements.
• The USDA approval process took approximately 6 weeks, during which we made adjustments to font sizes, product claims, and overall layout to comply with regulations.

Printing Proofs:

• Working with printing vendors, we conducted multiple proofing rounds to ensure accurate color reproduction. Color consistency is critical for brand identity, and we made precise adjustments to achieve perfection.

Final Production:

• Once the design was approved and proofed, we submitted the final files to the printing vendor. From there, production was ready to roll, ensuring Sear & Serve’s products would be shelf-ready by the deadline.

The Results

The entire process from design to production was completed in just four months, including the USDA’s six-week approval process. Our agile design and development approach ensured that we met every deadline without compromising on quality.

Key Results:

• Successful Product Launch: Sear & Serve’s new product line launched successfully and is now actively sold in major retail and club stores.
• Faster Time-to-Market: Despite a complex USDA approval process, the entire project was completed in just 4 months.
• Elevated Brand Perception: The sleek, premium design helped Sear & Serve establish a stronger retail presence and justify higher price points.

Key Takeaways

This case study highlights the importance of a strategic, process-driven approach to CPG packaging design. From concept to shelf, MOUZ Design provided end-to-end support, handling design, compliance, and production coordination. This holistic approach ensured that Sear & Serve’s launch was on time, on budget, and on brand.

Do you want your packaging to make an impact on store shelves? Contact MOUZ Design today to discuss your next big launch.