Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Jul 20, 2026

CASE STUDIES

 

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

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Project Overview

The packaging for the EDJY Toenail Cutter was designed to reflect the product’s focus on quality, functionality, and sustainability. By combining a premium rigid box structure with recycled materials and a minimalist visual design, the finished package delivers an elevated unboxing experience while reinforcing the brand’s eco-conscious positioning.

FEATURES

SUSTAINABILITY

SPECIALTY COATINGS

PAPERBOARD INSERT

OUR CAPABILITIES

Premium Rigid Box Construction

 

The package features a two-piece telescoping rigid box that provides durability and a high-end presentation. Constructed with recycled chipboard and wrapped with recycled paper, the box offers the strength and protection expected from rigid packaging while incorporating more sustainable materials. To improve usability, the lid includes integrated thumb notches that make opening the package easy and intuitive.

Product Protection & Presentation

 

Inside the box, a straight-tuck SBS insert with press-in cutouts holds the toenail cutter in place. The insert keeps the product centered and protected during shipping and handling while creating a clean, organized presentation when the package is opened. The simple, unprinted insert design complements the minimalist aesthetic of the overall package while ensuring the product remains the focal point.

Sustainable Material Choices

 

Sustainability was a key consideration throughout the packaging design. The use of recycled chipboard, kraft paper wrap, and a paperboard insert provide a 100% paper-based solution, while maintaining a premium appearance. The mono-material design helps maximize recyclability and is widely accepted in curbside recycling streams.

Minimalist Printing & Coating

 

The outer wrap features a minimal design printed using four-color process printing. Since the paperboard wrap is Kraft brown, we also printed two layers of white under the product image to provide brighter, more vibrant colors. Rather than covering the entire wrap with graphics, the design intentionally leaves much of the recycled paper exposed, allowing the natural texture to remain visible. This reinforces the package’s sustainable character and helps reduce overall ink usage.

A soft-touch coating is applied over the entire wrap to protect the printed graphics and provide a premium feel, while preserving the natural look of the paper. 

 

Results

 

The finished package successfully balances premium presentation with environmental responsibility. Through thoughtful material selection, minimalist graphics, and functional structural design, the EDJY Toenail Cutter rigid box creates a distinctive unboxing experience that aligns with the brand’s values while providing the protection and shelf appeal expected from a premium product.

Case Studies

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Dr. Squatch Discovery Pack Cologne Packaging

Dr. Squatch Discovery Pack Cologne Packaging

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Sustainable, Anti-Theft Packaging Redesign for PopSockets

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Jun 11, 2026

CASE STUDIES

 

Sustainable, Anti-Theft Packaging Redesign for PopSockets 

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The Challenge

PopSockets needed a new packaging solution for its PopGrips with Swappable Tops. Each package contained two interlocking components—a base and a top—and had to allow shoppers to see and interact with the product while it remained inside the package.

At the time, the product was packaged using a thermoformed plastic insert inside a folding carton. While this design provided a hands-on customer experience, it also created a significant retail challenge: the product could be removed too easily, leading to theft and product loss.

At the same time, PopSockets was working to reduce the environmental impact of its packaging by eliminating plastic components wherever possible.

The challenge was to create a packaging solution that improved security, supported sustainability goals, and still allowed customers to engage with the product before purchase.

FEATURES

COLD FOIL

SPECIALTY COATINGS

EMBOSSING

OUR CAPABILITIES

Structural Design

Wynalda Packaging developed a new structure built around a paperboard retention card that the PopGrip securely screws into. The card is enclosed within a windowed envelope-style folding carton that allows customers to see and touch the product while preventing it from being removed without damaging the package.

  

Sustainability

The redesigned package was manufactured using 100% recycled paperboard and was fully recyclable and FSC®-certified (FSC® C149826). By replacing the thermoformed plastic insert with a paperboard-based solution, PopSockets was able to eliminate plastic from the package and move closer to its sustainability objectives without sacrificing functionality or shelf appeal.

Printing

The project coincided with a broader brand refresh, requiring exceptional color accuracy across a wide range of SKUs.

Wynalda Packaging produced seven custom spot colors in-house, including five fluorescent inks, to achieve the vibrant appearance PopSockets was looking for. In addition, the packaging program included numerous licensed and co-branded product lines, including collaborations with Coca-Cola, Harry Potter, Vera Bradley, Peanuts, Marvel, Star Wars, and TikTok.

Maintaining consistent color reproduction across multiple brands, graphics, and product variations required careful color management throughout production.

 

Finishing & Embellishments

To enhance shelf impact, the packaging incorporated several premium finishing techniques.

A reticulating coating combined with spot gloss UV created visual contrast and tactile texture.

Cold foil was applied inline during printing to add metallic effects while maintaining production efficiency.

Select design elements were further enhanced through embossing, adding depth and dimension to the finished package.

Converting & Assembly

The package design required a specialized gluing and assembly process to achieve the desired structure at production speeds.

Custom converting techniques were used to accurately form the package, including a unique gluing sequence that allowed the structure to be assembled efficiently while securely retaining the product. Double-sided tape was incorporated to provide a reliable closure and ensure package integrity throughout distribution and retail handling.

 

The Results

The redesigned packaging successfully addressed all of PopSockets’ primary objectives: reducing theft, eliminating plastic, and maintaining hands-on product engagement.

The new structure made product removal significantly more difficult without damaging the package, helping reduce theft in retail environments.

Case Studies

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Dr. Squatch Discovery Pack Cologne Packaging

Dr. Squatch Discovery Pack Cologne Packaging

VIEW ALL CASE STUDIES

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Secondary Packaging for Maker’s Mark Wood Finishing City Series

May 19, 2026

CASE STUDIES

 

Secondary Packaging for Maker’s Mark Wood Finishing City Series

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Project Overview

ADM partnered with Wynalda Packaging to develop secondary packaging for the Maker’s Mark Wood Finishing City Series — exclusive New York and Sydney editions featuring cask-strength, locally inspired bourbons available only in their respective airports. The packaging was designed to reflect the premium nature of the collection while creating strong shelf presence for travelers seeking a unique, destination-specific offering.

FEATURES

CUSTOM PANTONE COLORS

DULL VARNISH

EMBOSSING

OUR CAPABILITIES

Structure & Materials

The package is constructed from 24pt SBS, featuring an auto-bottom folding carton with a gusset-tuck top and reinforced side walls to provide added strength and durability for the bottle during transportation and retail display.

 

Printing & Finishing

To maintain consistency with both the bottle design and the Maker’s Mark brand identity, the carton is printed using three Pantone colors: Maker’s Mark signature red, a custom black, and a custom cream background carefully color-matched to the bottle label. To reinforce the natural, wood-inspired aesthetic of the Wood Finishing Series, black graphics were used to create a tree-ring pattern across the top of the box, along with fine fiber detailing throughout the background to emulate the look of textured paper. A dull varnish was applied to enhance the organic appearance and provide a refined matte finish.

Embossing

Selective embossing was added to key text elements on the front panel to create depth, dimension, and a tactile, premium feel that elevates the overall presentation.

 

Conclusion

This packaging solution combines durable structure, refined print execution, and thoughtful finishing details to support the premium positioning of the Maker’s Mark Wood Finishing City Series. The result is a distinctive retail package that captures the craftsmanship and exclusivity of the collection while delivering a polished consumer experience.

Case Studies

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Dr. Squatch Discovery Pack Cologne Packaging

Dr. Squatch Discovery Pack Cologne Packaging

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Dr. Squatch Discovery Pack Cologne Packaging

Dr. Squatch Discovery Pack Cologne Packaging

Apr 9, 2026

CASE STUDIES

 

Dr. Squatch Discovery Pack Cologne Packaging

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Project Overview

 

Dr. Squatch, a fast-growing men’s personal care brand known for its rugged, natural aesthetic, required a premium packaging solution for their new Cologne Discovery Pack, designed to hold either three or five sample-size bottles of their Natural Cologne scents.

The packaging needed to deliver a high-end brand experience while aligning with the company’s sustainability values and aggressive product launch schedule. In addition to aesthetics, the project required tight coordination between design, manufacturing, and supply chain teams to ensure reliable execution ahead of the holiday selling season.

The brand required packaging that:

  • Utilized eco-friendly and responsibly sourced materials
  • Was produced by a domestic manufacturing partner to reduce risk and improve speed-to-market
  • Coordinated manufacturing within a timeline for a national holiday product launch
  • Maintained the premium look, feel, and brand consistency of their existing product line
  • Provided structural integrity to protect glass bottle during shipping and handling

Wynalda delivered a thoughtfully engineered packaging solution that combined sustainable materials with advanced manufacturing techniques, and precise structural design. The final package securely houses each bottle while creating an engaging unboxing experience that reflects that brand’s rugged, natural identity and supports efficient, scalable production.

FEATURES

CUSTOM MOLDED PULP

HOT FOIL STAMPING

EMBOSSING

OUR CAPABILITIES

Rigid Box

The outer package is a two-piece telescoping rigid box with an integrated platform, designed to align visually with Dr. Squatch’s existing packaging portfolio. It is constructed with 60 pt W1S recycled chipboard, providing the rigidity and durability required to protect fragile glass bottle throughout distribution and fulfillment. The 80# text wrap is printed on Wynalda Packaging’s Landa S11 Digital Offset Press, achieving six custom colors, and coated with a dull varnish for a refined, matte finish.

 

Embossing to Mimic Stock Texture

To maintain visual consistency with Dr. Squatch’s established packaging, the wrap material needed to replicate a specific textured surface used across their product line. Because a domestically sourced paper stock with that exact texture was not available within the required timeline, Wynalda’s team developed a process to emboss the entire sheet, recreating the desired texture while maintaining production efficiency and domestic sourcing requirements.

Hot Foil Stamping

After embossing, the wrap was hot foil stamped with design elements featuring fine lines and intricate details. Applying foil over a textured surface required precise control of pressure, temperature, and dwell time to ensure consistent adhesion and sharp visual detail.

“Throughout the project, we closely monitored the depth and consistency of the embossed texture to ensure it met both visual and tactile expectations. In addition, the customer required fine type foil stamping over the textured surface. This presented a unique challenge, as we needed to ensure proper foil adhesion on the embossed sheet while still maintaining crisp detail and the level of brilliance the customer expected.”

– Charles, Die Cutting & Stamping Manager

 

Molded Pulp Insert

Inside the box, a custom molded pulp tray securely holds the cologne bottles. Made from 20% recycled material, incorporating scrap solid bleached sulfate (SBS) generated from Wynalda’s own folding carton manufacturing process.  This closed-loop approach reduces material waste while supporting sustainability goals.

Structural Design Process

During the development process, Wynalda’s engineering team created and sent several iterations of 3D-printed samples to be tested for product fit and presentation. Once the structure of the tray was finalized, the team produced prototypes for a transportation study to ensure durability and performance.

Pulp Tray Masks Provide Versatility

To minimize tooling and production costs, Wynalda designed a single universal molded pulp tray that could be used for both the 3-bottle and 5-bottle discovery packs. We developed two different SBS masks for the pulp trays: one exposing all five cavities, and one exposing only three. The masks are printed with four-color process plus two custom colors and finished with dull varnish. They are then die-cut and glued to the molded pulp trays.

 

The Result

The final package successfully balanced sustainability, structural performance, and premium branding. The textured rigid box, detailed foil stamping, and molded pulp insert work together to create a high-end presentation with eco-conscious materials. The packaging met Dr. Squatch’s holiday launch timeline, delivered the brand experience they were looking for, and provided the flexibility needed for multiple product configurations.

Case Studies

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Dr. Squatch Discovery Pack Cologne Packaging

Dr. Squatch Discovery Pack Cologne Packaging

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Don Julio’s 1942 Tequila Gift Box

Don Julio’s 1942 Tequila Gift Box

Feb 19, 2026

CASE STUDIES

 

Don Julio’s 1942 Tequila Gift Box

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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

OUR CAPABILITIES

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.

Case Studies

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Dr. Squatch Discovery Pack Cologne Packaging

Dr. Squatch Discovery Pack Cologne Packaging

VIEW ALL CASE STUDIES