Manufacturing Process

Here at Wynalda Packaging, from Design to Fulfillment, we own the manufacturing process. With over 55 years in packaging, we have perfected our process to optimize quality and lead times for our customers. We are proud of our continuous investment in state-of-the-art equipment and technology.

Structural & Graphic Design

Great packaging requires a perfect blend of both structural design and visual appeal. The design needs to be sturdy enough to protect its contents during transportation and handling, while allowing for easy assembly, filling, and closure. A well designed carton will enhance the user experience, while also maximizing space efficiency for storage and display. Additionally, innovative structural designs can differentiate a product on the shelf, attracting consumer attention and providing an increased perceived value. At Wynalda, our team creates designs that balance all of these elements and are manufacturable at scale.

Graphic design is essential for branding and marketing. The visual elements on a folding carton, such as typography and imagery, communicate the brand’s identity and values. Effective graphic design can make a product stand out among competitors, convey important information, and create an emotional connection with consumers.

Wynalda’s team of designers can provide prototypes and detailed renderings before production begins. Additionally, digitally printed samples may be produced for review to ensure a seamless transition from conceptual development to final product.

In-House Prepress & Proofing

The Prepress Team at Wynalda Packaging transforms digital designs into print-ready formats. This includes several critical tasks, such as verifying the layout of the graphic elements, adjusting files to suit Wynalda’s printing methods, and ensuring the designs are optimized for the specific material being used, whether it’s paperboard, plastic, or foil.

The Prepress Team works closely with designers and clients to ensure that the final printed product meets all branding and quality expectations. This involves color management to ensure consistency across multiple print runs, proofing to catch any errors before production, and creating print plates. By making our own print plates  utilizing our in-house computer-to-plate (CTP) technology, we are able to offer faster production times, reduced costs, increased flexibility, and improved print quality.

By meticulously preparing and proofing all elements before printing, the prepress department helps avoid costly mistakes, reduces production lead-times, and ensures that the final packaging is visually appealing. Our proofing capabilities include both water-based and solvent-based Epson systems, providing accurate color representation. For added convenience and security, digital files can be securely uploaded to our FTP site for seamless processing.

Precise Color Matching and Custom Ink Production

Housed within our manufacturing facility is our on-site Ink Room. This department formulates inks to ensure precise color matching and consistency across various substrates and different production runs. The Ink Room is responsible for keeping colors consistent with customers’ requirements, brand guidelines, and industry standards. This includes performing color adjustments and creating custom inks for unique applications.

By preparing and delivering the necessary inks to the production floor, the Ink Room plays a critical role in preventing downtime, ensuring that printing operations proceed smoothly without any delays related to ink supply or quality.

8-Color Printing

Wynalda Packaging is committed to providing the highest quality print packaging to our customers. In order to do so, we utilize multiple offset printing presses in our manufacturing. Offset printing offers several advantages:

 

  • Superior image quality: Offset printing produces sharp, clean, and high-quality images with excellent detail and color accuracy.
  • Consistency: Whether we’re producing a few thousand or several million pieces, Wynalda’s offset presses ensure color and image quality are maintained from the beginning to the end of each production.
  • Fast production: Once the print plates are prepared, the printing process is quick, allowing for efficient manufacturing of large print jobs.
  • Broad printing surfaces: Offset presses are capable of printing on a variety of materials, including paperboards, plastics, and even metallic surfaces.

 

Our advanced printing technologies allow us to print up to 8 colors in a single pass. Our presses also have the capability to print with specialty UV and aqueous coatings, as well as cold foil, providing opportunities to create unique, premium packaging.

In-House Die Cutting & Die Making

At Wynalda Packaging, our in-house die making and die cutting teams are key elements of our commitment to delivering custom packaging with precision, speed, and superior quality to our customers.

By maintaining a fully equipped die shop, we design, manufacture, and adjust custom dies in-house. This allows us to significantly reduce lead times and enhance our quality control.  

Our die making and die cutting process ensures that every folding carton we produce is crafted to exact specifications, providing consistent, high-quality results while keeping costs down. 

Rigid Box Manufacturing

With a focus on quality and craftsmanship, Wynalda’s rigid boxes are designed to provide both durability and elegance, making them ideal for luxury items such as cosmetics, electronics, and specialty goods. We produce a wide variety of custom rigid set-up boxes, including styles such as telescoping, game board, and drawer designs.

After the chipboard box is constructed, we apply a sheet paper wrap. This wrap can be printed with your design and enhanced with specialty coatings, foil, and embossing. We also have the option to add magnets for secure closure.

Rigid box manufacturing further enhances our ability to serve diverse industries with sophisticated, tailored packaging solutions that elevate brand presentation and protect products.

Custom Molded Paper Pulp Trays

Molded paper pulp packaging marks an exciting expansion into additional sustainable and eco-friendly packaging solutions for our customers. With molded pulp, Wynalda is able to offer biodegradable and recyclable packaging options, ideal for companies looking to reduce their environmental impact.  

Molded pulp offers protective, custom-fit packaging for a wide range of products and can include your branding and designs. Made from up to 100% recycled content, including paper waste collected from our own manufacturing facilities, paper pulp packaging offers a sustainable alternative to traditional plastic, foam, or styrofoam inserts.

Custom Thermoformed Trays

Thermoforming is used to create plastic packaging, such as blister packs and custom inserts. This custom-fit, protective, and visually appealing packaging is a great way to hold and display products, while enhancing product and brand presentation.

At Wynalda, we offer recyclable options, numerous color choices, and high-impact or flame-retardant plastics. We provide custom molds and can work with a wide variety of thicknesses to meet your specific needs. We produce 3D prototypes for your approval, ensuring you get precisely what you envision.

Custom Injection Molded Packaging Parts

Wynalda Packaging offers total packaging solutions, which includes producing injection molded components that can be used to elevate your overall packaging presentation.

We use injection molding techniques to produce highly precise, custom packaging components such as branded hang tabs, lids, trays, or other complex parts.

Rigorous QA Testing

Our Quality Assurance (QA) Team is vital to our success, as they ensure that products manufactured at Wynalda Packaging meet the highest standards of performance, consistency, and quality.

The QA Team is responsible for inspecting raw materials, monitoring production processes, and conducting final product checks to guarantee that every carton adheres to specifications in terms of dimensions, functionality, print quality, color accuracy, and structural integrity. Their role in preventing defects and identifying potential issues early in the production process minimizes waste, reduces costs, and avoids delays.

Additionally, the Quality Team ensures compliance with industry regulations and customer requirements, further enhancing trust and maintaining Wynalda’s reputation for reliability.

Packaging Enhancements

Our packaging specialties allow us to produce unique and creative packaging that contributes to consumer confidence in our customers’ brands, creating added value for our customers.

Specialty UV & Aqueous Coatings

Specialty coatings can be applied during printing to enhance both the visual appeal and functionality of packaging. Some of the most commonly used specialty coatings at Wynalda Packaging include:

 

  • Gloss: provides a high-shine finish and intensifies colors.
  • Matte: offers a non-reflective, smooth finish that gives a sophisticated look and feel.
  • Soft-Touch: gives the printed surface a velvety, soft texture that creates a sensory experience.
  • Pearlescent: contains reflective particles giving the packaging a subtle shimmer.
  • Reticulating: uses a UV curing technique to create a textured surface.
  • Spot UV: applied to specific areas of the printed cartons to create contrast with other finishes and highlight certain design elements. 

 

Whether using just one, or combining multiple specialty coatings, they can be used to add depth, texture, and protection to packaging, helping brands achieve a distinct, high-quality finish tailored to their unique needs and marketing position.

In-Line, On-Press Cold Foil Printing

Applying cold foil as part of the printing process enhances printed packaging with metallic effects, adding a luxurious, eye-catching finish. In cold foil printing, adhesive is applied in the desired locations while on press and metallic foil is transferred onto the adhesive. This method allows for fine details, intricate patterns, and vibrant colors, as the foil can be overprinted with inks to create a wide range of metallic hues.

Commonly used on packaging for cosmetics, luxury goods, and high-end consumer products, cold foil helps create a premium look that stands out on the shelves. Additionally, cold foil is more eco-friendly compared to traditional hot foil stamping, as it typically generates less waste and is applied in-line during the printing process, streamlining production.

Foil That Draws Attention and Adds Authenticity

Hot foil stamping is a process where metallic foil is applied to packaging, creating a high-quality, reflective finish that adds elegance and distinctiveness to the product, grabs attention, and enhances your product’s perceived value.

Hot foil stamping offers a wide range of foils including golds, silvers, holographic foils, and extensive color options. Foil stamping is commonly used in packaging for cosmetics, wine, and spirits, among other high-end goods. It can be combined with embossing to create a raised, tactile feel, further enhancing the sense of quality. Though it’s more time intensive than cold foiling, hot foil stamping delivers unmatched depth, texture, and durability, making it a popular choice for premium packaging.

Beyond aesthetics, foil stamping also serves as a powerful security feature. Integrating security elements within the foil can ensure product authenticity, reassuring customers that they have the genuine item, not a counterfeit.

Embossing & Debossing

Embossing and debossing are two techniques in packaging manufacturing used to add depth, texture, and tactile elements to designs, enhancing both visual and physical appeal. These applications add a unique sensory experience, making the packaging not only look appealing but also feel distinctive in the consumers hands. At Wynalda, we offer a range of embossing and debossing options.

Embossing creates a raised effect, making specific design elements such as logos or patterns stand out. Embossing is often combined with other finishes such as specialty coatings or hot foil stamping to further accentuate the raised elements, adding a luxurious touch and making the packaging more engaging for customers.

Debossing creates a recessed effect by pressing the design into the packaging’s surface. Debossing provides a subtle, sophisticated look that emphasizes detail and depth without necessarily catching light as embossing does. The effect can be used alone, or can be paired with matte or gloss finishes to create contrast.

Cellophane Windows and Rigid Waterfall Windows

Incorporating windows into the packaging’s design allows consumers to see the product inside without opening the package. This design feature is highly effective in boosting product appeal and building consumer trust.  

The use of windows in packaging serves several purposes that include:

 

  • Product transparency: letting consumers see the actual product, reassuring them of its quality and appearance.
  • Enhanced visual appeal: by giving a “sneak peek” of the product, windows add a visual element that can make packaging more attractive on the shelf, grabbing attention of the consumer amongst competing items.
  • Brand trust: transparent windows allow brands to showcase the quality of the product openly, which fosters trust and conveys authenticity.
  • Reduced need for imagery: with a visible product, there’s less reliance on photos or illustrations, allowing for simpler, cleaner graphical design while still highlighting key features.
  • Customizable options: windows can be cut into various shapes and positioned strategically to emphasize specific product details.  

 

Wynalda Packaging developed Wynview™, a unique waterfall-style rigid window application which provides an elegant display of the product from several angles.

Steel and Magnet Application For Secure Closure

Magnetic closures in folding cartons or rigid boxes adds a premium, innovative touch that enhances both functionality and aesthetics. Incorporating small magnets into the packaging creates a secure closure that offers several benefits, including enhanced consumer experience, reusability, and brand differentiation.

Serialization & Ink Jetting

Serialization involves the application of unique identifiers such as serial numbers or redemption codes on each individual package, adding traceability and security across the supply chain. Our ink-jetting machine can also print barcodes or QR codes onto packaging.

Key benefits to serialization include:

 

  • Product authentication: unique serial numbers enable consumers and retailers to verify the authenticity of a product, helping to prevent counterfeiting and ensuring brand trust.
  • Supply chain transparency: serialized cartons can be tracked at every stage from manufacturing to distribution, providing visibility and reducing the risk of diversion or theft.
  • Regulatory compliance: in sectors such as pharmaceuticals, serialization is often mandated by regulatory bodies to ensure accurate tracking and traceability, helping manufacturers meet compliance standards.
  • Enhanced consumer engagement: serialized codes, such as QR codes, can connect consumers to digital experiences like product information or loyalty programs, creating an interactive and informative brand experience.
  • Quality control and recall management: serialization allows manufacturers to identify and isolate specific batches or units if a recall is necessary, minimizing impact and enhancing safety.

 

Supply Chain Solutions

From vendor managed inventory programs to complex global security, we offer a variety of supply chain solutions to help you navigate the rapidly changing demands of the consumers.

Custom Vendor Managed Inventory Programs

Wynalda Packaging offers custom Vendor Managed Inventory (VMI) programs to help optimize efficiencies in supply chain operations. Depending on the unique specifications laid out in each program, we produce packaging and store it for future release.

This proactive offering provides several key advantages that include:

 

  • Improved inventory availability: With VMI programs, Wynalda can monitor stock levels closely, ensuring consistent supply and reducing the risk of stockouts. This leads to fewer interruptions in production and fulfillment, which is particularly crucial during peak demand seasons.
  • Reduced inventory costs: VMI programs minimize overstock and reduce the need for large safety stocks, which translates to lower holding costs for our customers.  
  • Optimized supply chain efficiency: Customers benefit from efficient, just-in-time replenishment, which reduces lead times and ensures that packaging arrives exactly when needed.
  • Enhanced forecasting and planning: VMI programs use real-time data, allowing for anticipated demand changes and adjusting inventory levels accordingly. This helps maintain optimal stock levels even during seasonal fluctuations or unexpected shifts in demand.
  • Streamlined operations: VMI programs can simplify order processing and logistics, reducing administrative burdens and allowing for more focus on core business activities.

 

Hand Work, Packout, and Delivery

Beyond packaging manufacturing, Wynalda offers fulfillment services to provide end-to-end solutions, streamlining the supply chain, and improving efficiency for brands. Our team can handle assembly, packaging, shrink-wrapping, and delivery—all under one roof. With our secure facilities, you can rest assured that your product is well-protected throughout the entire process. 

Benefits of utilizing this service are:

 

  • Reduced operational costs: By consolidating packaging and fulfillment, brands can save on warehousing, labor, and logistics costs. 
  • Speed-to-market: Managing fulfillment in-house allows Wynalda to streamline the process for our customers, accelerating the speed-to-market timeframe which is critical for seasonal and high-demand products.
  • Scalability: Fulfillment service allows brands to scale operations smoothly, accommodating seasonal demand or promotional campaigns without needing additional resources or warehouse space.
  • Enhanced customer experience: With Wynalda handling fulfillment, we create tailored unboxing experiences, adding inserts, branded materials, or personalized touches that increase customer satisfaction.

Global Supply Solutions for US, Asia, and Beyond

Wynalda International, a sister company of Wynalda Packaging based in Hong Kong and Shenzhen, China is capable of meeting your overseas packaging needs on a global scale.

Working with a manufacturer such as Wynalda that can produce packaging in both the United States and Asia offers the following benefits:
Quality control: Regardless of the manufacturing location, all packaging adheres to Wynalda’s strict quality standards. You can press-proof your product here in the US, then confidently produce it in China, providing assurance that the final product will match your expectations.
Easier communication: All conversations to the international team are handled via our domestic office. This is crucial in being able to discuss complex projects, adjust for last minute changes, and keep lead-times as short as possible.

For more details on our international capabilities, visit Wynalda International.

Maximum Brand and Product Security

Wynalda prioritizes the security of our customers, their brand, and products from production to delivery. All of Wynalda’s manufacturing and warehouse facilities are monitored under 24/7 surveillance and undergo third party audits to reduce the risk of counterfeiting.

Beyond the physical goods, extensive measures are also taken to protect intellectual property and offer data security.  Our enhanced cybersecurity practices ensure that sensitive information is protected from breaches and unauthorized access.

Track & Trace Solutions

Wynalda Packaging partners with Aletheia Security & Fulfillment to provide track and trace capabilities for our customers. Our track & trace solutions use QR codes and serialization to deliver advanced supply chain traceability–from the manufacturing floor to the consumer’s hands. The QR codes are scanned at every checkpoint, recording the date, time, location, and device, allowing you to see the full journey of your product. This is beneficial for several reasons:

 

  • Anti-Diversion: Codes can be tied to specific regions, retailers, or channels, and scans outside of assigned markets trigger alerts, helping maintain pricing integrity and authorized distribution.
  • Recall Management & Batch Control: Rapidly trace defective items by batch, enabling precise recalls and efficient root cause analysis.
  • Inventory & Warehouse Optimization: Codes enable real-time stock tracking across supply chain nodes, reducing manual errors and stockouts, and improving warehouse and fulfillment operations.
  • Consumer Engagement & Tracking: Location data from consumer scans gives brands full, end-to-end visibility into a product’s journey. When a customer scans a QR code with their phone, they are instantly connected to content such as promotions, loyalty programs, product guides, etc. These experiences not only boost engagement and improve the user experience, but they also encourage more scans, enabling brands to gather rich, actionable data.
  • Regulatory Compliance: Timestamped data supports audits and traceability standards, and region-specific landing pages for consumer scans ensure local regulation compliance.

 

While most of the features mentioned above can be achieved using batch QR codes, serialized QR codes take supply chain traceability a step further. With serialization, each package is printed with a unique QR code. These codes unlock detailed product-level data that can be accessed through a simple scan, offering several benefits, especially for high-value and high-security items:

 

  • Anti-Counterfeiting: Each unique code can be scanned to verify authenticity through a secure brand-managed database, and duplicate or invalid codes flag possible counterfeits.
  • Unit Tracking: Serialization allows you to monitor the movement of individual units during and after production.
  • Precise Quality Control: With serialized QR codes, you’re not limited to batch-level traceability. You can drill down even further, identifying issues linked to a specific machine or shift, for fast, targeted problem-solving.
  • Point-Based Rewards Systems: Consumers can claim rewards points by scanning the unique QR code on their packaging. This adds incentive to scan the code, providing consumer scan data for full lifecycle visibility.

Custom Anti-Diversion & Anti-Counterfeit Strategies

Implementing anti-diversion and anti-counterfeiting practices into product packaging is essential for protecting brand integrity and consumer safety. 

A few effective strategies that are commonly used at Wynalda Packaging are:

 

  • Unique serialization: Unique serial numbers or codes are printed onto each carton, enabling traceability and verification at various points in the supply chain.
  • Tamper-evident features: Packaging structures can be designed to offer evidence of the carton being opened or altered, deterring tampering.
  • Holographic security: We can incorporate holograms or 3D security features that are difficult to replicate, making it easier to identify authentic products.
  • Invisible inks: Invisible inks that can be viewed under certain UV light or with digital readers can serve as a hidden identifier for authentic products.
  • RFID technology: Radio frequency identification (RFID) tags can be applied in-line during the packaging manufacturing process. These tags allow products to be tracked throughout the supply chain through real-time monitoring and authentication.
  • QR codes: printing QR codes that can be scanned by consumers to verify product authenticity or access additional product information.

 

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