Think Tank

Think Tank’s approach to sustainable packaging

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Emilie Eisenberg learns how British packaging designer Think Tank is using 3D design to elevate its work for clients


Thinking of gifting some perfume this Christmas? Or maybe you’ll be handed a free T-shirt at some event, or splash out on a scarf that shows your support for a particular football team? If so, Think Tank might well be involved somewhere along the line.

Since 1999, the company has produced high-end packaging for brands that include Ralph Lauren, Ted Baker, Formula One, Coca-Cola and Manchester City. In 2024, Think Tank marked its 25th anniversary and the team there has much to celebrate.

“At the heart of our company’s ethos is our name,” says head of creative production Nick Seston. This, he explains, brings together ‘think’, symbolising the realm of ideas and creativity, and ‘tank’, representing an engine that brings ideas to life, “through coordination with suppliers and streamlined logistics.”

Each project is designed alongside the relevant client, in a process that includes researching existing designs, new materials and current trends. The goal: to develop packaging that will intrigue and entice customers.

All wrapped up

Designs built in Rhino 3D are subsequently moved into 3D renders and videos using Keyshot, in order to demonstrate to the client how the final product will look.

By opting for rendering instead of prototyping, designs can be edited and changed as many times as a client likes, tweaking small features until they are 100% satisfied.

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A final prototype is then made, using the client’s choice of materials. This might range from card and paper to organic textiles. What’s important is that the prototype accurately demonstrates what the final product will look and feel like. Before manufacturing begins, further edits and new prototypes may be made.

Due to the company’s commitment to sustainable packaging, Think Tank encourages clients to opt for recycled or biodegradable materials where possible, Seston says. “Over the past few years, we have seen a noticeable shift towards paper, card and organic textures, as companies become more concerned about their impact on the planet. We have also made a pronounced effort to move away from designs that require large moulds, as this process produces far more waste than other methods.”

He continues: “We always advise recycled content options and urge clients to avoid using plastics in laminations, as well as other unsustainable processes, such as foam fitments. To ensure manufacturing is as sustainable as possible, Think Tank only uses accredited factories with which it has long-standing relationships.”

Think Tank – Smart supply chains

Manufacturing a wide range of products, Think Tank works directly with suppliers in order to maintain quality control. A core supply chain produces card, paper, packaging and textiles in various locations, both in the UK and in other locations around the world, depending on client requirements.

“The long-term relationships we have fostered with our suppliers are vital to creating top-quality products and packaging, so this is the best way to ensure we never have to compromise on quality,” says Seston.

The length of a manufacturing process will vary. Initial prototypes can be produced within a week, followed by an open-ended consultation period. Urgent print work can be completed in a few days, and larger orders can be completed in under 12 weeks.

Think Tank is already looking towards the future with the launch of its SMART packaging format, which blends physical packaging with digital content by using digital access codes that can be activated using a smartphone.

“It’s a really exciting moment, as SMART formats will help our clients elevate their packaging design and boost their commercial reach,” Seston explains.

For now, guiding customers to more sustainable solutions is one of Think Tank’s main priorities. The team may not be able to reveal what’s currently in the works – its projects are kept under wraps until they hit the shelves – but it’s more than likely that SMART formats will add some extra excitement to this company’s highly visual packaging solutions.


This article first appeared in DEVELOP3D Magazine

DEVELOP3D is a publication dedicated to product design + development, from concept to manufacture and the technologies behind it all.

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