Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Feb 5, 2026

CASE STUDIES

 

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

BACK TO CASE STUDIES

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

OUR CAPABILITIES

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.

Case Studies

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Cigarette-Style Perforated Boxes for AdvoCare

Cigarette-Style Perforated Boxes for AdvoCare

Cold Foil Boxes for Don Julio

Cold Foil Boxes for Don Julio

Custom Magnetic Closure Box With Waterfall Window

Custom Magnetic Closure Box With Waterfall Window

VIEW ALL CASE STUDIES

Cigarette-Style Perforated Boxes for AdvoCare

Cigarette-Style Perforated Boxes for AdvoCare

Jan 20, 2026

CASE STUDIES

 

Cigarette-Style Perforated Boxes for AdvoCare

BACK TO CASE STUDIES

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

OUR CAPABILITIES

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.

Case Studies

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Cigarette-Style Perforated Boxes for AdvoCare

Cigarette-Style Perforated Boxes for AdvoCare

Cold Foil Boxes for Don Julio

Cold Foil Boxes for Don Julio

Custom Magnetic Closure Box With Waterfall Window

Custom Magnetic Closure Box With Waterfall Window

VIEW ALL CASE STUDIES

Cold Foil Boxes for Don Julio

Cold Foil Boxes for Don Julio

Dec 12, 2025

CASE STUDIES

 

Cold Foil Boxes for Don Julio

BACK TO CASE STUDIES

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

OUR CAPABILITIES

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.

 

Case Studies

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Cigarette-Style Perforated Boxes for AdvoCare

Cigarette-Style Perforated Boxes for AdvoCare

Cold Foil Boxes for Don Julio

Cold Foil Boxes for Don Julio

Custom Magnetic Closure Box With Waterfall Window

Custom Magnetic Closure Box With Waterfall Window

VIEW ALL CASE STUDIES

Custom Magnetic Closure Box With Waterfall Window

Custom Magnetic Closure Box With Waterfall Window

Dec 11, 2025

CASE STUDIES

 

Custom Magnetic Closure Box With Waterfall Window

BACK TO CASE STUDIES

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

OUR CAPABILITIES

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.

Case Studies

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Cigarette-Style Perforated Boxes for AdvoCare

Cigarette-Style Perforated Boxes for AdvoCare

Cold Foil Boxes for Don Julio

Cold Foil Boxes for Don Julio

Custom Magnetic Closure Box With Waterfall Window

Custom Magnetic Closure Box With Waterfall Window

VIEW ALL CASE STUDIES
Limited Edition Packaging for Goose Island Beer Co.

Limited Edition Packaging for Goose Island Beer Co.

Dec 11, 2025

CASE STUDIES

 

Limited Edition Packaging for Goose Island Beer Co.

BACK TO CASE STUDIES

Project Overview

 

ADM partnered with Wynalda Packaging to create luxury, stand-out packaging for the limited edition release of Goose Island Beer Co.’s King Henry II Barrel-Aged Barleywine. The goal was to design a structure and finish that reflected the rarity and craftsmanship of the beer, delivering an elevated and memorable unboxing experience.

To achieve this, Wynalda developed a custom drawer-style rigid box paired with a paperboard slipcase and a layered insert, combining structural creativity with refined detailing for a truly luxurious presentation.

FEATURES

SPECIALTY COATINGS

EMBOSSING

COLD FOIL

OUR CAPABILITIES

Rigid Box

 

A rigid box serves as the primary structural element for this package, constructed from 60pt chipboard with both an outer wrap and inner liner. 

  • Inner Liner: printed with 2 PMS colors and coated with an overall soft-touch coating.
  • Outer Wrap: printed with 4-color process plus 2 PMS colors and coated with an overall soft-touch coating.
  • Enhancements: Cold foil accents add depth and a rich metallic sheen, underscoring the exclusivity of the King Henry II release.

Paperboard Insert

 

Inside the rigid box rests a three-layer 18pt SBS insert, each layer precisely cutout revealing the layer beneath, creating a sense of depth and dimension. Printed with 3 PMS colors, cold foil, and an overall soft-touch coating, the insert maintains the cohesive aesthetic of the full package. A lift tab adds functionality and ensures a seamless unboxing experience. Achieving perfect registration across all layers required meticulous gluing and alignment, demonstrating Wynalda Packaging’s attention to detail and manufacturing precision.

Paperboard Slipcase

 

The outer slipcase was designed to make an immediate impression. Crafted from 18pt SBS, it features a rolled edge bottom and tuck top with a tongue lock for secure closure. Cut-outs on the front and back of the slipcase add another layer to the dimensional reveal. 

 

 

 

In tandem with the rest of the package, the slipcase features gold cold foil, 2 custom PMS colors, and an overall soft-touch coating. For the final touch, blind embossing adds a tactile, elegant finish that communicates luxury from the first glance.

The Result

 

The final package stands as a testament to collaboration, precision, and design excellence. Through the combination of thoughtful structure, rich materials, and luxurious finishes, Wynalda Packaging helped ADM and Goose Island transform a limited-edition beer into an unforgettable brand experience. 

 

Case Studies

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Cigarette-Style Perforated Boxes for AdvoCare

Cigarette-Style Perforated Boxes for AdvoCare

Cold Foil Boxes for Don Julio

Cold Foil Boxes for Don Julio

Custom Magnetic Closure Box With Waterfall Window

Custom Magnetic Closure Box With Waterfall Window

VIEW ALL CASE STUDIES