Knob Creek Gift Set Windowed Rigid Box
The Challenge
Disney approached Wynalda Packaging with a creative vision: to design a Lion King collector’s edition DVD set packaged inside a box that looks like a drum. This unique concept posed multiple challenges. The circular shape of the drum was not ideal for shipping and limited the amount of space available for branding or promotional content. To address these issues, the drum would need additional outer packaging. Disney also envisioned the packaging as being part of the collector’s item, something fans would proudly display rather than discard after opening. Therefore, the outer packaging had to complement the drum design while being aesthetically pleasing enough for people to want to showcase.
Features
Embossing
Hot Foil Stamping
Specialty Coatings
The Solution
Wynalda’s design team crafted a stunning packaging solution that fulfilled all of Disney’s objectives. The packaging included an outer rigid box with a hinged door panel that opened to reveal the drum, which housed a paperboard disc booklet. To provide additional branding and promotion space, the entire set was wrapped in a paperboard belly band.
The outer rigid box was designed to look like carved wood. To recreate this effect, we wrapped the chipboard box in a sheet of paper that had been embossed across the entire surface. Because of the large surface area, depth, and detail of the emboss, this process required significant pressure. Initially we tried embossing 100# C1S to wrap around the chipboard, but we found that it did not retain the desired level of detail after being wrapped. To resolve this, we switched to 100# MPE, which held the embossing much more effectively, giving the box a rich texture. We then printed the MPE with a solid white layer to eliminate any shine, followed by four-color process to create the wood grain design, and finished it with a dull varnish. The combination of deep embossing, printing, and coating resulted in a box that looked and felt like carved wood.
For a unique display experience, we designed a hinged door that could slide into the side of the box and disappear, perfectly showcasing the drum inside. This hidden door could be pulled back out using the attached ribbon tab. To prevent the door from completely coming out of the box when sliding it out, we designed a paperboard locking mechanism for the door. Another ribbon was added to the inside of the box to make it easier to pull the drum out of the box. The inside of the box was lined with 60pt black chipboard, forming a neck ring around the opening of the box, which allowed the door to be recessed and flush with the outside of the box.
To create the drum-shaped box, we wrapped 80# C1S around a chipboard cylinder. The drum was capped on both ends with uncoated kraft to replicate the leather ends of a traditional drum. The top and bottom trays fit together so that they were flush with one another, creating a smooth surface. The C1S was printed with four-color process, coated with a dull varnish, and embossed to give the drum strings a realistic texture.
Inside the drum, we developed a paperboard booklet that fanned out and held the eight discs from the Lion King Collector’s Edition. This booklet could be fastened with velcro straps and was seated securely in a custom-designed foam insert wrapped in solid black paperboard and placed inside the bottom tray.
Finally, to add more in-store branding and promotion, we added a printed paperboard belly band, finished with hot foil to add a bit of shine.
The Results
The Lion King Collector’s Edition packaging was a resounding success. Disney’s vision for a unique and display-worthy box was brought to life, with intricate details and materials that truly embodied the luxury and collectability they sought. The drum-shaped box, combined with the clever outer packaging design, not only solved the shipping and branding issues but also elevated the product into a showpiece that fans could proudly display.
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