Refining the Torch Sushi Takeout Experience from Kraft to Custom

For a takeout brand, the box is the dine-in experience delivered, so it has to carry the weight of the food without failing and still look the part at the door. Torch Sushi, a returning PakFactory customer, came back with three things to solve.

• Could it carry the weight without curving?
  An earlier kraft box looked great but flexed under the food.
• Would it be safe for direct food contact?
  Anywhere the food touched the box needed a food-grade surface.
• Could it present premium yet ship affordably?
  The box had to look refined without running up freight costs.

Their first version used a kraft box that customers loved for its natural feel, but the stock was too thin to hold the food without bowing. We recommended Torch Sushi to move to a sturdier 400gsm paperboard and a 6-corner structure, a format built to carry weight, so the box can keep its shape under a full order of pressed sushi.

Because the packaging is in direct contact with food, it carries a food-grade PE lining wherever the sushi meets the box, along with a food-grade insert sized to the rolls, so the contents stay protected and safe in transit.

The 6-corner box ships flat rather than pre-assembled, which keeps freight and storage costs down without changing the look, an approach we walked Torch through so the savings did not cost them presentation. The finish was refined over time from an aqueous semi-gloss to a clean matte, and the same design carried across three box sizes for their different formats.

6 corner food grade sushi take out box

Cardboard insert

Food-grade PE, wax lining

Torch Sushi came away with a takeout box that travels well, keeps food safe, and looks like the restaurant behind it, across every size on the menu. It is why they keep coming back to PakFactory to refine and reorder as the brand evolves.