Nescafe Azera – Coffee Cap

Branded Nescafe Azera coffee overcaps moulded in LLDPE.

Nescafe Azera – Coffee Cap

The Brief

When Nestle UK transferred manufacture of Nescafe Azera, the hugely popular Barista style instant coffee to their Tutbury site, they took the opportunity to review the packaging. The distinctive metal can is popular with consumers.  However, the Nescafe Azera marketeers were anxious to improve the merchandising opportunities in retail outlets via better on-shelf stacking. Nestle worked collaboratively with Robinsons to provide a brand new, innovative design.

Our Solution

Robinsons solution was to use in-house CAD design and model making ability to design and develop a lighter weight overcap.  The cap has a special function that enables cans to securely stack on top of each other. We also proposed that the branding of the cap could be significantly enhanced at a low cost by adding a large embossed Nescafe Azera logo on the top surface of the caps.


The dedicated tool is cleverly designed to allow Nestle to introduce other branding options for the same cap.  As and when different variants were to be added to the range the design could easily be amended. Robinson coordinated the commissioning of new caps. They were seamlessly phased into Tutbury, without the need for any line changes. As part of an ongoing cooperation with the local site team, the transit packaging for the caps was also modified.  The company would no longer permit the use of wooden pallets in production areas.


“We are delighted with the new cap, and with the pro-active approach shown by Robinson throughout the project”.

Mike Peplow, Nestle.