CASE STUDIES
Sustainable, Anti-Theft Packaging Redesign for PopSockets
The Challenge
PopSockets needed a new packaging solution for its PopGrips with Swappable Tops. Each package contained two interlocking components—a base and a top—and had to allow shoppers to see and interact with the product while it remained inside the package.
At the time, the product was packaged using a thermoformed plastic insert inside a folding carton. While this design provided a hands-on customer experience, it also created a significant retail challenge: the product could be removed too easily, leading to theft and product loss.
At the same time, PopSockets was working to reduce the environmental impact of its packaging by eliminating plastic components wherever possible.
The challenge was to create a packaging solution that improved security, supported sustainability goals, and still allowed customers to engage with the product before purchase.
FEATURES
COLD FOIL
SPECIALTY COATINGS
EMBOSSING
Structural Design
Wynalda Packaging developed a new structure built around a paperboard retention card that the PopGrip securely screws into. The card is enclosed within a windowed envelope-style folding carton that allows customers to see and touch the product while preventing it from being removed without damaging the package.
Sustainability
The redesigned package was manufactured using 100% recycled paperboard and was fully recyclable and FSC-certified (FSC® C149826). By replacing the thermoformed plastic insert with a paperboard-based solution, PopSockets was able to eliminate plastic from the package and move closer to its sustainability objectives without sacrificing functionality or shelf appeal.
Printing
The project coincided with a broader brand refresh, requiring exceptional color accuracy across a wide range of SKUs.
Wynalda Packaging produced seven custom spot colors in-house, including five fluorescent inks, to achieve the vibrant appearance PopSockets was looking for. In addition, the packaging program included numerous licensed and co-branded product lines, including collaborations with Coca-Cola, Harry Potter, Vera Bradley, Peanuts, Marvel, Star Wars, and TikTok.
Maintaining consistent color reproduction across multiple brands, graphics, and product variations required careful color management throughout production.
Finishing & Embellishments
To enhance shelf impact, the packaging incorporated several premium finishing techniques.
A reticulating coating combined with spot gloss UV created visual contrast and tactile texture.
Cold foil was applied inline during printing to add metallic effects while maintaining production efficiency.
Select design elements were further enhanced through embossing, adding depth and dimension to the finished package.
Converting & Assembly
The package design required a specialized gluing and assembly process to achieve the desired structure at production speeds.
Custom converting techniques were used to accurately form the package, including a unique gluing sequence that allowed the structure to be assembled efficiently while securely retaining the product. Double-sided tape was incorporated to provide a reliable closure and ensure package integrity throughout distribution and retail handling.
The Results
The redesigned packaging successfully addressed all of PopSockets’ primary objectives: reducing theft, eliminating plastic, and maintaining hands-on product engagement.
The new structure made product removal significantly more difficult without damaging the package, helping reduce theft in retail environments.
