A U.S. Amazon seller needed a custom sugarcane bagasse meal box that could carry food and a beverage cup in one integrated package.

After developing the first custom mold, pack-level testing revealed that the cup-holder sections nested too tightly when the products were stacked. Ancheng revised the cup-holder geometry and added anti-nesting features to improve separation while maintaining a secure fit for the beverage cup.

The revised samples met the customer’s requirements, received final approval and proceeded to a formal order.

 

Project Overview

 

Customer: U.S. Amazon seller   
Product: Custom bagasse clamshell meal box   
Application: Combined food and beverage packaging   
Customization: Integrated cup holder, product dimensions, structure and molded logo   
Packing format tested: 25-piece stacks   
Main challenge: Products nested too tightly around the cup-holder section   
Solution: Revised cup-holder taper and anti-nesting features   
Result: Final sample approval and formal order

 

Customer Background

 

The customer sells food packaging products through Amazon in the United States. To expand its product range, the customer wanted to develop a distinctive molded fiber package that combined a clamshell meal box with an integrated beverage holder.

The product needed to make it easier for consumers to carry a meal and drink together. It also required custom dimensions, a unique structure and a logo formed directly into the mold.

 

The Custom Product Requirement

 

The customer’s proposed product included two connected sections:

- A rectangular clamshell compartment for food 
- A round integrated holder for a beverage cup 
- A hinged bagasse lid 
- Custom product dimensions and shape 
- A molded customer logo inside the lid 
- A structure suitable for stacking, packing and online distribution

Ancheng translated the customer’s concept into a custom mold and prepared samples for evaluation.

 

The Stacking Challenge

 

The first samples demonstrated the intended appearance and basic function. However, the customer identified an important issue when the products were packed in stacks of 25.

The cup-holder sections nested too tightly. Although an individual sample appeared normal, the packed products were difficult to separate efficiently and the cup-holder area could become damaged during removal.

The issue could not be evaluated accurately by looking at a single product. Ancheng therefore reviewed the complete stacking condition and compared the cup-holder geometry with an earlier sample that separated more easily.

 

Identifying the Cause

 

The original cup holder had a top diameter of 8.5 cm and a bottom diameter of 7.5 cm. This limited difference created a relatively straight sidewall, allowing adjacent products to fit too closely together during stacking.

Increasing the distance between the products with a deeper projection was considered, but an excessive gap could cause the clamshell section to tilt or distort.

The solution therefore needed to achieve three results:

- Maintain the required cup opening 
- Make stacked products easier to separate 
- Keep the cup-holder and meal-box sections level during packing

 

Ancheng’s Structural Solution

 

### Revised Cup-Holder Taper

Ancheng retained the 8.5 cm top diameter to preserve compatibility with the intended beverage cup.

The bottom diameter was reduced from 7.5 cm to 6.5 cm. This created a steeper cup-holder wall and reduced the contact between adjacent products, allowing them to separate more easily after stacking.

The 6.5 cm bottom diameter remained large enough to support the customer’s intended cup.

### Added Anti-Nesting Features

Ancheng also added small anti-nesting features to the molded structure.

These features created controlled spacing between adjacent products and helped keep the cup-holder section aligned with the main clamshell compartment. This prevented the stack from becoming uneven, with one side sitting higher than the other.

### Updated Mold Design

Because the changes affected the production mold, Ancheng prepared an updated design drawing for customer confirmation before proceeding.

The revised mold incorporated:

- A smaller cup-holder bottom diameter 
- A more suitable sidewall taper 
- Anti-nesting features for controlled separation 
- Improved alignment between the cup holder and food compartment 
- The required molded logo

## Pack-Level Sample Verification

The revised design was not evaluated only as a single product. Ancheng prepared another sample package of 25 pieces to reproduce the customer’s actual packing and handling conditions.

This allowed the customer to check:

- Separation between adjacent products 
- Cup-holder integrity during removal 
- Stack alignment 
- Product stability during packing 
- Fit with the intended beverage cup

The revised samples separated correctly and satisfied the customer’s requirements.

 

Final Product Solution

 

The completed solution included:

- Sugarcane bagasse clamshell construction 
- Integrated food compartment and beverage holder 
- 8.5 cm cup-holder top diameter 
- Revised 6.5 cm cup-holder bottom diameter 
- Improved cup-holder taper 
- Molded anti-nesting features 
- More stable 25-piece stacking 
- Custom dimensions and product shape 
- Custom logo formed directly into the mold

 

Project Result

 

Ancheng converted the customer’s concept into a production-ready bagasse meal box with an integrated cup holder.

When the first samples revealed a separation problem under actual packing conditions, the team analyzed the cup-holder geometry and developed a targeted mold modification. The revised taper reduced excessive nesting, while the added anti-nesting features kept the products level and easier to separate.

The customer approved the improved samples and placed a formal order.

 

What Made This Project Successful

 

### 1. Testing Under Actual Packing Conditions

The stacking problem did not appear when inspecting a single sample. Evaluating the product in a 25-piece pack allowed the team to identify how the cup holders behaved under the customer’s real packing conditions.

### 2. Measurable Structural Adjustment

Ancheng did not rely on a general shape change. The team retained the required top opening and reduced the bottom diameter by 1 cm, creating a more suitable taper while maintaining cup compatibility.

### 3. Controlled Product Separation

The added anti-nesting features maintained space between adjacent products and improved stack alignment. This helped protect the cup-holder section during packing and removal.

### 4. Customer Coordination Before Mold Modification

The revised dimensions and structural features were documented in an updated drawing before the mold was changed. This gave the customer an opportunity to review the proposed solution and reduced uncertainty during the final sample round.

 

Develop Custom Bagasse Packaging for Your Product

 

Need a bagasse meal box with a custom compartment, integrated cup holder, molded logo or application-specific structure?

Share your product concept, dimensions, cup size, packing quantity and intended use with Ancheng. Our team can evaluate the structure, develop the mold and prepare samples under your actual packing conditions.