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.

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

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.

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.

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.