Modular Rigid Box Packaging for TruDiagnostic
The Challenge
EDJY, a trailblazer in premium nail care products, introduced the first-ever single-blade nail cutter engineered for clean, precise cuts without crushing nails. Their commitment to innovation and exceptional user experience doesn’t stop at the product itself—it extends to every brand touchpoint, including their packaging.
EDJY desired a new packaging solution that:
- Distinguishes EDJY from competitors with a design unlike anything on the market.
- Holds the product securely while opening and closing seamlessly.
- Provides a unique and engaging unboxing experience.
- Reflects the premium nature of EDJY’s product.
- Upholds EDJY’s sustainability standards.
Features
Recyclable
Biodegradable
Embossing
Our Solution
Wynalda’s Design Team delivered a custom-engineered packaging system that checked every box, blending innovation, performance, and sustainability into a cohesive design.
Packaging Structure
Molded pulp trays are traditionally used as box inserts or clamshells, but Wynalda’s Design Team created an innovative hybrid packaging structure that integrates molded paper pulp with a book-style paperboard wrap. The molded pulp tray is affixed to the back panel of the wrap, which folds around the tray and seals, forming a self-contained unit that offers both presentation and protection. This design provides generous printable space on both the interior and exterior, maximizing branding and storytelling opportunities. During fulfillment, the package is securely closed using wafer seals, keeping the product safe while streamlining EDJY’s pack-out process.
Molded Paper Pulp Tray
Made from 100% virgin fiber, the tray is pressed to an ultra-smooth finish to convey a refined look and feel, while maintaining durability with a 0.8mm wall thickness. The custom-formed tray is fully recyclable and biodegradable, providing a sustainable alternative to the plastic clamshells commonly seen in personal care and beauty packaging. Each tray is wash-trimmed for clean, uniform edges. The manufacturing process for the molded pulp utilizes a recycled water tank system, reducing water consumption and environmental impact.
Paperboard Wrap
To elevate shelf appeal, and give the packaging a natural look, the wrap is crafted using 18pt KraftPak paperboard. It is printed with EDJY’s minimalistic design and coated with a dull varnish only on the printed elements, allowing the natural fiber texture of the paperboard to be emphasized. This approach reduces ink and coating use, enhances recyclability, and contributes to the packaging’s eco-minded aesthetic. To elevate the design further, the card is embossed, creating a striking, dimensional effect that makes the product image on the front truly stand out.
The Result
The new packaging accomplishes every functional and branding goal, all while upholding EDJY’s sustainability standards.
100% Paper-Based Packaging: All components are biodegradable and recyclable within a single stream—no material separation required.
50% Material Reduction: Compared to their previous rigid setup box design, the new packaging solution cuts material weight in half, from 0.10 lbs to 0.05 lbs, resulting in improved transportation logistics and a lower carbon footprint.
Cost-Effective, Domestic Solution: By eliminating the rigid box and transitioning to molded pulp and paperboard, EDJY reduced their packaging costs while still delivering a premium experience to their customers. All packaging manufacturing took place at Wynalda’s Michigan facility, using domestically sourced materials, aligning with EDJY’s commitment to American-made excellence.
Conclusion
EDJY’s packaging now mirrors the ingenuity of their product—luxurious, sustainable, and unmistakably original. It’s a compelling story in how eco-conscious materials and clever structural design can work together to create an impactful customer experience.
Need help transforming your packaging? Wynalda’s experts are ready to collaborate on your next big idea. Let’s talk!
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