Project: FreshFill — A Better Frozen Sandwich for All
The Challenge
Families love the convenience of frozen PB&J sandwiches, but current market leaders like Uncrustables are often high in sugar, overly processed, and unaffordable for many. How might we develop a healthier, affordable, and exciting frozen sandwich that appeals to low-to-mid income families in the Midwest?
The Insight
Through AI-powered market research and user behavior analysis, we discovered:
Parents want better nutrition without sacrificing speed and portability.
Kids love fun, familiar formats, but are open to new flavors if subtly introduced.
There’s a rising demand for allergen-free, plant-based, and whole grain options in school lunches.
Convenience wins — prep-free, lunchbox-ready solutions are essential for busy families.
The Problem
Current frozen sandwich options like Uncrustables dominate the market but fall short in several key areas:
Nutritional Gaps: High in sugar, processed ingredients, and lacking in whole food benefits.
Limited Variety: Few flavor or dietary options, excluding families with allergies or special diets.
Affordability Barrier: Prices are often too high for low-income families seeking daily convenience.
Lack of Innovation: The format hasn’t evolved to reflect modern health trends, sustainability, or cultural diversity.
Concept Development
Solution &Outcome
We delivered a product line system called FreshFill™, positioned as the next-gen healthy frozen sandwich alternative with:
Modular flavor strategy to appeal to picky eaters and health-conscious parents
Smart packaging concepts that emphasize visibility of ingredients and fun usage (lunchbox-ready packs)
Flexible manufacturing roadmap using co-packers and existing cold chain logistics
Retail strategy focused on regional Midwest grocers and discount retailers (Aldi, Meijer, Kroger)
In-store display concepts for compact POP bins and school lunch aisle integration
