Don Julio’s 1942 Tequila Gift Box

Don Julio’s 1942 Tequila Gift Box

CASE STUDIES

 

Don Julio’s 1942 Tequila Gift Box

Project Overview

ADM partnered with Wynalda Packaging to develop premium secondary packaging for Don Julio’s iconic 1942 tequila bottle as part of its 2025 holiday program. The goal was to create a visually striking carton that elevated shelf presence and positioned the tequila as a festive gift.

FEATURES

SPECIALTY COATINGS

COLD FOIL

DEBOSSING

Structure & Materials

The carton was produced using 28pt SBS C1S and engineered with an auto-lock bottom and tuck-top closure. This structure delivers exceptional strength and stability while supporting efficient assembly.

 

Printing & Cold Foil

To achieve a refined metallic aesthetic, cold foil was applied to the top half of the carton, then overprinted with a custom gold PMS color and finished with spot gloss. This layered approach created a foil effect that perfectly aligns with Don Julio’s signature branding. The bottom half of the carton was printed in Don Julio’s iconic brown using four-color process and finished with a dull varnish, delivering richness, contrast, and depth.

 

Debossing

Across the top half of the carton, a debossed groove pattern was incorporated to add visual and tactile interest. Extending across the box folds, the deboss required meticulous attention to detail and precise registration. Accentuated by the cold foil and spot gloss, the detail reinforces the carton’s luxurious look and feel.

 

Result

The finished package delivers a sophisticated yet festive, gift-worthy presentation that commands attention at retail while staying true to Don Julio’s iconic brand identity.

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

CASE STUDIES

 

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Project Overview

Adrian Costa, a new fragrance brand launched in October 2025 in partnership with Perfumania, set out to create packaging with an elevated, luxury look and feel. 

While the brand recognized the perceived value of and premium feel of rigid boxes, the challenge was to deliver that experience using responsible, paper-based materials throughout.

FEATURES

SPECIALTY COATINGS

COLD FOIL & HOT FOIL

MOLDED PULP INSERT

Rigid Box

The rigid box is constructed from 60pt recycled chipboard (W1S) and wrapped in 80# white text, with precision skived corners that deliver sharp, clean edges on the box’s exterior.

The lid is printed with four-color process plus a custom PMS red and finished with a soft-touch coating. Cold foil was applied inline during printing and overprinted to create a custom foil tone, creating a subtle metallic sheen across the background. Select design elements were further enhanced with post-press hot foil stamping, adding depth and a rich, reflective contrast.

The base is printed in the custom PMS red and finished with a soft-touch coating, completing a cohesive, premium presentation.

Advanced rigid box equipment forms lids and bases simultaneously and joins them inline with robotic automation, ensuring tight tolerances, consistency, and production efficiency.

 

Molded Pulp Insert

The molded pulp insert is pressed to an ultra-smooth, premium finish with a 1mm wall thickness, providing strength and protection for the bottle.

The insert contains 20% recycled material, and production utilizes a recycled water tank to reduce overall water consumption.

Sustainability

The entire package is 100% paper-based, fully recyclable, and manufactured in the USA at Wynalda Packaging’s Michigan facility.

The Result

The final package delivers a refined unboxing experience that captures attention at retail while offering environmental responsibility.

By combining advanced manufacturing, premium finishes, and sustainable materials, this packaging solution reinforces Adrian Costa’s commitment to sustainability while elevating perceived retail value.

Looking to elevate your fragrance packaging? Connect with a packaging expert to explore premium, sustainable solutions tailored to your brand.

Cigarette-Style Perforated Boxes for AdvoCare

Cigarette-Style Perforated Boxes for AdvoCare

CASE STUDIES

 

Cigarette-Style Perforated Boxes for AdvoCare

Project Overview

AdvoCare, a premium dietary supplement brand, partnered with Wynalda to create retail packaging for their new powdered kombucha supplement, Harmony®.

The packaging had to securely hold 15 individual stick packs while delivering:

  • A convenient, user-friendly experience
  • A refined, high-end presentation
  • Strength and durability

FEATURES

SPECIALTY COATINGS

PERFORATION

CUSTOM SPOT COLORS

Cigarette-Style Perforated Box

 

To achieve these objectives, Wynalda Packaging designed a cigarette-style perforated box made from 24pt SBS. The design features an auto-lock bottom for added strength and fulfillment efficiencies, while a perforated flip-top lid allows consumers to store the box in their cupboard and easily remove one stick pack at a time. 

Inner Collar

 

To enhance the strength and maintain the box’s shape after opening, we added a three-panel inner collar that lines the front and sides of the box, forming an internal support wall that reinforces the structure and ensures a secure closure for the lid.

Printing & Coating

 

Color accuracy was critical for AdvoCare’s brand. The carton was printed using four PMS colors plus black, then finished with a soft-touch coating and spot gloss UV to achieve a refined, tactile finish.

 

 

The Result

 

The final result delivered on every objective, combining strength, aesthetic appeal, and functionality. AdvoCare was thrilled with the Harmony packaging and is now exploring the same design for other product lines.

Cold Foil Boxes for Don Julio

Cold Foil Boxes for Don Julio

CASE STUDIES

 

Cold Foil Boxes for Don Julio

Project Overview

ADM Group partnered with Wynalda Packaging to develop a premium secondary packaging solution for Don Julio’s iconic 750ml bottles of Tequila Reposado and Tequila Blanco.

The goal was to design a visually striking box that not only reflected the premium quality of the tequila but also aligned seamlessly with the branding of the bottle and label inside.

FEATURES

SPECIALTY COATINGS

WINDOW CUT-OUT

COLD FOIL

Structure & Materials

 

To deliver the strength and durability needed to support the bottle’s weight, we engineered a folding carton from 28pt SBS, featuring a reinforced auto-lock bottom structure and partitioned dust flaps to hold the bottle securely in place. A circle window cut-out allowed the elegant bottle design to remain visible, reinforcing shelf appeal and brand recognition.

Printing & Finishing

 

To complement the gold foil accents on the bottle’s label, we used cold foil printing to add a metallic sheen to key design elements on the box. The box was printed using four-color process plus a custom gold spot color over the foil to perfectly match the gold foil on the label. The box was finished with an overall matte varnish, providing a sophisticated look and feel.

Conclusion

 

The final result was a cohesive, eye-catching promotional package that elevated Don Julio’s brand while ensuring product protection and retail impact.

 

Custom Magnetic Closure Box With Waterfall Window

Custom Magnetic Closure Box With Waterfall Window

CASE STUDIES

 

Custom Magnetic Closure Box With Waterfall Window

Project Overview

 

Blue Force Gear, a leading manufacturer of lightweight, modular tactical gear, was looking to elevate the unboxing experience for their Trauma Kit. Previously packaged in a simple poly bag, the brand wanted a solution that offered stronger shelf presence, enhanced branding, and distinct packaging for each SKU.

To help Blue Force Gear meet these goals, Wynalda Packaging developed a premium straight tuck carton made of 18pt SBS.

FEATURES

SPECIALTY COATINGS

WATERFALL WINDOW

MAGNETIC CLOSURE DOOR

Waterfall Window

 

This carton featured a two-panel waterfall window to showcase the pouch color, as the kit is available in multiple colors. Using 7mm APET, the window was die cut and applied using pick-and-place technology to achieve the waterfall effect.

Magnetic Closure Door

 

Since much of the front panel space was occupied by the window, we added a door with magnetic closure, creating extra real estate for messaging and product details while maintaining product visibility.

Custom Hang Tab

 

For retail versatility, we added a custom-designed injection-molded hang tab.

 

 

Printing & Coating

 

The carton was printed using four-color process with the addition of Blue Force Gear’s signature PMS blue. A soft-touch coating added a sleek, matte texture, while spot gloss UV created eye-catching contrast on key design elements.

SKU Differentiation

 

To accommodate product differentiation, the contents of each SKU were printed directly on the packaging. For their customizable Trauma Kit SKU, a blank space was reserved on the back for a label detailing the customer-selected contents.

 

 

Conclusion

 

This solution delivered a substantial upgrade in both form and function, improving brand perception, enhancing SKU distinction, and offering an engaging unboxing experience that reflects the premium nature of Blue Force Gear’s products.