Zenlock: Sustainable Child-Resistant Packaging

Zenlock: Sustainable Child-Resistant Packaging

Zenlock: Sustainable Child-Resistant Packaging

https://youtu.be/RJi_Mw2DXdk

Zenlock is a system of pre-certified cannabis packages made using mainly paper products. In an industry dependent upon plastic child-resistant mechanisms, Zenlock stands out as an all-paper solution that can be recycled along with the most common household paper products, including newspapers and paper pulp. The packages are made using post-consumer recycled material without the need for any specialized manufacturing processes. The flexible design limits dead space and weight while maximizing printable area, allowing for the most compact box for different scenarios and brand messaging. Only soy-based inks are used for printing. Additionally, the sturdy boxes can be reused while maintaining their child-resistant functionality.

In 2021, Zenlock was awarded Third Place in the Plastic Free category at The Dieline Awards and a Shortlist Certificate in the Sustainable Design category by Pentawards. Zenlock is currently in the process of receiving an official Plastic Free Certification Mark from A Plastic Planet.

The first branded Zenlock packages are currently in production for multiple cannabis brands throughout California.

Zenlock is a system of pre-certified cannabis packages made using mainly paper products. In an industry dependent upon plastic child-resistant mechanisms, Zenlock stands out as an all-paper solution that can be recycled along with the most common household paper products, including newspapers and paper pulp. The packages are made using post-consumer recycled material without the need for any specialized manufacturing processes. The flexible design limits dead space and weight while maximizing printable area, allowing for the most compact box for different scenarios and brand messaging. Only soy-based inks are used for printing. Additionally, the sturdy boxes can be reused while maintaining their child-resistant functionality.

In 2021, Zenlock was awarded Third Place in the Plastic Free category at The Dieline Awards and a Shortlist Certificate in the Sustainable Design category by Pentawards. Zenlock is currently in the process of receiving an official Plastic Free Certification Mark from A Plastic Planet.

The first branded Zenlock packages are currently in production for multiple cannabis brands throughout California.

In 2020, California passed regulations requiring that all cannabis products must be enclosed in child-resistant packaging. After analyzing the legislature, other CR packages and testing requirements, the results were clear: too much plastic and too many overly complicated CR mechanisms. The three design requirements also became clear: recycled and recyclable materials only, elevated product presentation, and flexible CR to accommodate diverse needs for cannabis products.

Most child-resistant mechanisms on the market are physically and cognitively difficult to operate. While inhibiting children is the goal, physically challenging packaging can affect broader accessibility. In response, the industry needed human-centered packaging featuring a mechanism that is sensitive and discrete without being physically taxing. After multiple prototypes with simple 2-part opening sequences, the final Zenlock system was born. It balances graphics and mechanics to be intuitive for adults yet impenetrable to young hands.

The mechanism and instructional graphics are strategically placed so that the entire box can be used for branding with high-quality print finishes. The rigid box also provides structure and stability, giving weight to the premium goods inside. And every Zenlock box is constructed using post-consumer recycled paper.

Zenlock can be made with standard packaging production equipment and requires only simple die tooling. Unlike other injection-molded parts, an all-paper based design allows for minimal material for the tooling. The paper substrate is printed with soy-based ink at an efficient speed.

Zenlock created a mechanism that can be easily scaled to fit different products. This flexible design means we can create the most compact box for different scenarios, limiting dead space, waste of material, and efficient shipping.

Zenlock is a response to the lack of paper based options in the CR packaging industry. We created Zenlock with 94% paper-based materials and the remaining 6% biobased or water-soluble for easy curbside recycling. Zenlock materials breakdown:

SBS – 10%, virgin pulp, no recycle content
Greyboard – 84% (100% post-consumer recycled content)
Glue – 2%, water-based
Ink – 1%, soy-based
Biodegradable plastic film – 3%*

* Zenlock's biodegradable plastic lamination is designed to dissolve in paper pulp recycling machines.

Note: The image with printed graphic boxes depict a conceptual brand.

In 2020, California passed regulations requiring that all cannabis products must be enclosed in child-resistant packaging. After analyzing the legislature, other CR packages and testing requirements, the results were clear: too much plastic and too many overly complicated CR mechanisms. The three design requirements also became clear: recycled and recyclable materials only, elevated product presentation, and flexible CR to accommodate diverse needs for cannabis products.

Most child-resistant mechanisms on the market are physically and cognitively difficult to operate. While inhibiting children is the goal, physically challenging packaging can affect broader accessibility. In response, the industry needed human-centered packaging featuring a mechanism that is sensitive and discrete without being physically taxing. After multiple prototypes with simple 2-part opening sequences, the final Zenlock system was born. It balances graphics and mechanics to be intuitive for adults yet impenetrable to young hands.

The mechanism and instructional graphics are strategically placed so that the entire box can be used for branding with high-quality print finishes. The rigid box also provides structure and stability, giving weight to the premium goods inside. And every Zenlock box is constructed using post-consumer recycled paper.

Zenlock can be made with standard packaging production equipment and requires only simple die tooling. Unlike other injection-molded parts, an all-paper based design allows for minimal material for the tooling. The paper substrate is printed with soy-based ink at an efficient speed.

Zenlock created a mechanism that can be easily scaled to fit different products. This flexible design means we can create the most compact box for different scenarios, limiting dead space, waste of material, and efficient shipping.

Zenlock is a response to the lack of paper based options in the CR packaging industry. We created Zenlock with 94% paper-based materials and the remaining 6% biobased or water-soluble for easy curbside recycling. Zenlock materials breakdown:

SBS – 10%, virgin pulp, no recycle content
Greyboard – 84% (100% post-consumer recycled content)
Glue – 2%, water-based
Ink – 1%, soy-based
Biodegradable plastic film – 3%*

* Zenlock's biodegradable plastic lamination is designed to dissolve in paper pulp recycling machines.

Note: The image with printed graphic boxes depict a conceptual brand.

https://thezenlock.com/