ZERO PLASTIC LUNCHWARE

The ZERO PLASTIC lunchware range was developed through a careful design process with a clear objective: to eliminate all plastic from the product while maintaining everyday usability. It evolved from an earlier Victorian Premier’s Design Award-winning range, but this time with a stricter materials approach and a deeper focus on health and environmental outcomes.

The process began with feedback from existing customers, combined with ongoing research into the effects of microplastics and the limitations of plastic-based foodware. These insights shaped a brief that prioritised performance, durability, and food safety, delivered through materials not traditionally used in this category.

Material selection was a core part of the process. After researching options, the solution centred around food-grade stainless steel, tempered glass, and silicone. Each material had to meet practical requirements like microwave and dishwasher safety, ease of cleaning, and resistance to odour and staining.

One of the main challenges was replacing the plastic lid. Tempered glass, while safer than untreated glass, needed protection and sealing. The solution was to encase the glass in a custom silicone surround, which solved multiple issues at once: creating a leak-proof seal, allowing air to escape on closure, removing the need for clips. While also protecting the edges from breakage.

Built-in dividers were replaced with removable silicone compartments, offering more flexibility for packing and reheating. The design was refined over several rounds of prototyping and use testing, with adjustments made to fit, feel, and ease of cleaning.

Final components were tooled and sourced through established suppliers, and the product was brought to market with plastic-free packaging.

The result is a professionally resolved product that meets the original design brief and introduces meaningful improvements. It demonstrates that plastic-free foodware can meet real-life needs without compromise.

The ZERO PLASTIC range was developed with a practical focus on durability, safety, and real-world usability. While the design reflects a cleaner, more refined aesthetic, the visual outcome is a byproduct of function-led decisions, not styling for its own sake.

Every part of the product was considered with the user in mind. The stackable silhouette fits neatly into fridges, bags, and dishwashers. The stainless steel base is stain-resistant and easy to clean, and an optional ceramic-lined version offers even easier cleaning.

The tempered glass lid is permanently encased in silicone, which improves stacking, prevents slipping, and cushions the glass against knocks. This same silicone border also forms an air tight seal when applying the lid, all without the need for clips or manual valves.

User feedback played a key role in decisions such as replacing fixed dividers with removable silicone inserts. This allows for more flexible packing, such as separating hot and cold items—and makes it easier to reheat only part of a meal.

The final result is intuitive to use and suits a broad range of users, from families to office workers. Materials were chosen not only for safety but for longevity. All components are food-safe, BPA-free, and compliant with international standards. Replacement parts extend the product’s usable life, reducing unnecessary waste.

The range aims to set a benchmark for how mainstream foodware can be made responsibly. It avoids disposable patterns of use by offering a product that performs well, feels good to use, and fits easily into existing routines.

While the design is modest in appearance, the level of consideration and material integrity helps position it as a quiet but important step forward, not just in Victoria, but for all of Smash’s global retail partners.

The ZERO PLASTIC lunchware range addresses two ongoing problems in the foodware space: the widespread use of plastic in products marketed as reusable and the emerging health risks associated with microplastic exposure.

While many containers reduce single use waste, they often continue to rely on plastic in key areas such as seals, lids or compartments. This range takes a different approach by removing plastic entirely, offering a safer, longer-lasting option that maintains the convenience people expect.

A central innovation is the specially engineered stainless steel base that is microwave safe. Traditional stainless steel is not compatible with microwave use, but this version was carefully developed and tested to allow safe reheating without sparking or damage.

This capability allows users to move away from plastic without giving up the ability to quickly reheat meals, something that is often seen as non-negotiable in busy households and workplaces.

The use of a silicone-encased glass lid is another key feature. This single part performs multiple functions. It forms a reliable seal without the need for clips or valves, cushions the glass against knocks, and allows the containers to stack securely. This solves several practical issues typically handled by plastic components.

Flexible silicone compartments replace fixed dividers, allowing users to separate different foods, manage portion sizes, and microwave only what is needed. This supports more mindful food preparation and reduces unnecessary waste.

While the range does not claim to be the first of its kind, it demonstrates a clear shift in thinking. It proves that a fully plastic free container can still meet all the core needs of modern users.

The innovation lies in resolving familiar problems in a new way and offering a practical alternative that supports both personal wellbeing and environmental responsibility.

The shift to zero plastic solutions in a category traditionally dominated by plastic reflects a broader change in consumer expectations. Families and individuals are increasingly aware of the health risks linked to microplastics, particularly in food containers used for heating.

At the same time, concerns about the environmental cost of disposable and short life plastics continue to grow. This product responds to both issues with a practical and accessible solution that does not compromise performance or convenience.

The microwave safe stainless steel base represents a significant step forward in functionality, allowing users to reheat meals safely without relying on plastic. This supports both personal health and more responsible material use.

The inclusion of long life components that are modular, easy to clean, and replaceable supports extended use and helps reduce waste. From an environmental perspective, removing plastic from all major components, along with eliminating plastic from packaging, reduces reliance on petroleum based materials and lowers long term landfill impact.

The product follows circular design principles by using durable materials that support repeated use and longevity, with part replacement options available to help extend product life.

Commercially, the range has generated interest from retail partners who recognise its relevance in a changing market. There is a growing awareness across the market that foodware must evolve, and this design offers a timely and relevant alternative that aligns with those expectations.

As a product developed in Victoria, it reflects the state’s commitment to practical and thoughtful design. It demonstrates that investing in a professional and user focused process can lead to solutions that offer lasting benefits across health, sustainability, and everyday usability.

By rethinking something as ordinary as a lunchbox, this project contributes to a wider conversation about how responsible design can become part of everyday life.

This project was guided by a clear intention: to create a durable, plastic free lunchware range that would support long term use and reduce reliance on disposable or short life containers. The design balances environmental responsibility with real world practicality, making it easier for users to adopt more sustainable habits without sacrificing convenience.

From the outset, material selection was central to the process. All core components are made from stainless steel, tempered glass, and food grade silicone. These materials were chosen for their strength, food safety, and suitability for daily use.

Unlike many food containers that rely on layered plastics or coatings, this range avoids complex materials and minimises unnecessary parts.

Durability is built into every detail. The microwave safe stainless steel base resists stains and odours. The tempered glass lid, encased in a protective silicone surround, withstands regular use and travel. Modular silicone compartments allow flexible food separation and can be removed or replaced as needed.

These features help extend product life and reduce the likelihood of premature disposal. The product also avoids overdesign. Each component serves a clear purpose and is easy to clean, store, and use.

Packaging is plastic free and made from recyclable materials, reinforcing the commitment to responsible design from start to finish.

While not fully circular in a technical sense, the design follows circular principles by reducing waste, encouraging reuse, and supporting part longevity. It helps shift expectations around what everyday products can look like when designed with sustainability in mind.

By focusing on function, longevity, and material integrity, this project demonstrates that circular thinking can be applied to simple, practical objects in a way that feels familiar, affordable, and easy to adopt.