Client seeking technical design for food packaging for transporting fragile cake to retail outlets
Cake is 15 cm in diameter, flat top and 4 cm high. Each cake is cut into 6 even pieces. Individual pieces are placed on individual custom die-cut cake boards, each with a thumb handle. The base of the cake piece is stuck onto the surface of the cake board with glucose. The individual custom die cut cake boards look like this:
These are made from gold wrapped stiff board, about 2mm thick.
Each of the six individual pieces on the custom die cut cake boards are then slotted into a circular blister mould that looks like an empty pie chart. The dividers in the mould are about 4 mm high (or as low as possible really), with a toungue and groove mechanism in the vertical walls to hold the 2mm cake board in place. So in profile the mechanism woudl look like captial T's. The perimeter circle around the pie chart blister has the same tongue and groove mechanism, but there is a space for the thumb handle.
Then, if necessary (depending on how tight the blister is gripping the cake board) some form of lock is used to keep the backs of the 6 cake board locked into the blister. Some protective cover till need to be placed over the 6 pieces of cake (that cover could also serve as the lock).
When the cover is removed, and the cake is put on display, the shop assistant will need to be able to slide out an individual cake just holding the thumb handle without disturbing the other pieces, and without touching the cake being removed. So the grip of the blister tray on the cake board will need to be suitable so it slides easily, but not too easily. If it slides too easily, the individual pieces may slide out of the blister tray. If it it is too tight, the shop assistant will be liable to overpull and drop it. Ideally there woudl be somewhere to for the assistant to hold on the pie wheel to stabilise it when she is sliding out the piece.
The blister wheel will also need to be able to lock into, or fit into a cake box like this:
This part is important, but, it probably does not need anything custom.