Making Bun Boxes

Can you remember how Jamaican Easter buns were packaged?

For some of you those memories may be fading while for others it is still current.  Most times it was in a box. 

Bun Box from Jamaica

Wanting to relive this memory I decided that the Jamaican Products Easter buns should be packaged in a box.  Fortunately I brought a few Easter bun boxes from Jamaica, so I could well use those boxes.  But wait, I have to buy the bun tins in the shape of a bread loaf.

So off I went looking at the hospitality equipment shops.  Asking for bun tins got me a quizzical look, so I quickly asked for bread loaf tins instead.  Something I thought would be easy was turning into a challenge.  Back to the large department stores and I found a loaf tin that I was happy with.  It boasted a heavy duty seamless loaf tin with a double non-stick coating, ideal for making bread, meat/fruit loaf and pate.  Above all it could easily be used to make a 1.2kg loaf.

I bought 16 tins and went home pleased with myself.  But I only bought 10 bun boxes in Jamaica!  Are they large enough?  Alas the tins were about twice as wide as the boxes. 

Tin too large for Box

Now I need some 20 bun boxes.  I measured the newly purchased tins and started my Google search.  I was looking for food grade boxes to store buns baked in the tins.  I saw many square boxes but no rectangular boxes the shape I was interested in.  After over 3 hours searching, I started calling companies in Sydney that sold boxes. 

They were interested in making these boxes for me until I told them I only needed 20.  Do you mean 20,000 they asked?  No, I replied, I only need 20.  I know I could not afford a one off order when they quoted me the price while others  said they could not do such a small run.

Designing a Box

After spending the day searching and talking to various packaging firms I decided to produce a custom made box myself.  Now the search was on to find material to make this customised bun box.

Again I was googling and calling various shops, asking if they had necessary material or could advise where to obtain the material.  My search led me to Arts and Craft stores.  I needed material sturdy enough to hold the bun, a box design and glue to hold everything together. 

By the third day I was going home with cardboard sheets and glue to start the building process.  I was in my element as an engineer designing and later constructing bun boxes.   

The Pro Forma Design

It was out with my ruler, set square and drafting pens to draw my box to scale.  I did my measurements and drew up the box shape for cutting out as the pro forma.  Now it was time to consult my business cohort, Jean Kropper, on how to fold the cardboard.  Jean owns Paper and Pixel, making ingenious promotions in paper that excite the senses and inspire response. 

A Finished Box

Using the pro forma created as a guide I soon had 20 box frames marked and cut from the cardboard sheets.  Then it was folding and pasting to make each box.  To add that business touch I added the Jamaican Products logo.  After many hours the 20 Jamaican Products bun boxes were complete. 

Next job, to make the Easter buns for packing in these custom made bun boxes.  So wish me luck. 

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