Frozen food 260641

Packaging for frozen pizza and pastry: a series of boxes on a single structural design

Cardboard packaging for frozen products is a category of its own, with specific requirements: the box is stored at −18 °C, comes into contact with condensation, is stacked in freezer display cases — and must stay rigid, flat and presentable right up to the moment of purchase. In this project, the Pergament printing house (Chișinău, Moldova) produced a series of five boxes for a range of frozen pizza and pastry: Pepperoni, Quattro Carni, Quattro Formaggi, Adjarian khachapuri and pide with chicken fillet.

The structure is a flat, square pizza-style box measuring 305×305×25 mm, with a hinged lid and locking tabs. All five products are built on a single 676×395 mm blank: one cutting die serves the entire series, and the difference between the products is created by the printed design alone. For the client, this means substantial savings on die-cutting tooling and a consistent, instantly recognisable look for the whole range on the shelf. And if a project needs no new structure at all, a suitable box shape can be selected from the printing house’s library of over 3,000 ready-made cutting dies.

The material is dense 323 g/m² cardboard, 0.51 mm thick, with a white printable face and a kraft reverse side. It is precisely this high density that allows a wide, flat box to hold its shape in freezer conditions and protect the product from deformation.

The printing is offset, in the CMYK colour model, 4+0 — full colour on the outer face. On top of the print, in a single pass, a full-coverage gloss dispersion varnish is applied: a water-based, odourless coating approved for food packaging. The varnish protects the print from abrasion and moisture and gives the packaging a glossy, retail-ready finish — the illustrations on the box stay vivid even in a freezer display case, while the coating, applied inline with the printing, adds no separate production step to the cost.

After die-cutting, the boxes are assembled on an automated folding-gluing line using cold glue — the process is fully automated, guaranteeing consistent gluing quality across the entire series.

Order type — packaging. Full production cycle in Chișinău: prepress, offset printing, full-coverage gloss varnishing, die-cutting and automated folding-gluing. Pergament manufactures custom cardboard packaging for frozen products, pizza, pastry and other food products — from a single box with an individual design to multi-SKU series built on a shared structure.