Modular Rigid Box Packaging for TruDiagnostic

Modular Rigid Box Packaging for TruDiagnostic

CASE STUDIES

 

Modular Rigid Box Packaging for TruDiagnostic

The Challenge

 

TruDiagnostic, a leading health data company specializing in advanced biological age testing, needed a unified packaging solution for three distinct product versions: TruHealth, TruAge, and the TruDiagnostic Bundle. Their primary goals were to streamline their packaging across all versions while maintaining product distinction—all in a cost-efficient manner.

 

FEATURES

 

 

SPECIALTY COATINGS

 

 

COST EFFICIENCY

 

 

DURABILITY

Our Solution

 

Wynalda Packaging engineered a modular solution that streamlined production by using a single rigid box across all three product versions. Customizable paperboard sleeves and inserts provided the flexibility to differentiate each product, balancing cost efficiency with product distinction.

 

 

The solution included:

 

  • A rigid telescoping base-and-lid box crafted from .058 white-lined chipboard, wrapped in 80# text stock.
  • A custom O-sleeve made from 18pt SBS C1S, featuring vibrant 4-color printing, an overall dull varnish, and spot gloss UV to highlight brand elements.
  • A paperboard insert, also made from 18pt SBS C1S, printed in full color and finished with an aqueous gloss coating for a clean, professional look.

The Results

 

By standardizing the rigid box and allowing for interchangeable sleeves and inserts, this modular approach provided the flexibility to distinguish each product while capitalizing on economies of scale. It also streamlined inventory management and delivered a cohesive, elevated brand experience across all variants.

Ready to unlock packaging efficiencies that save time and costs? Connect with us today!

 

Jim Beam Bottle Hitchhiker Packaging

Jim Beam Bottle Hitchhiker Packaging

CASE STUDIES

 

Jim Beam Bottle Hitchhiker Packaging

Overview

 

ADM partnered with Wynalda Packaging to design a bottle hitchhiker for Jim Beam, one of the world’s most iconic bourbon whiskey brands. The hitchhiker hung from the neck of their 1.75-liter bourbon whiskey bottle and held a collapsible cooler as a promotional gift. This eye-catching packaging not only stood out on the crowded liquor aisle but also incentivized purchases by offering customers a free, practical gift with every bottle.

FEATURES

SPECIALTY COATINGS

STRUCTURAL DESIGN

DURABILITY

Structure & Materials

 

The hitchhiker was engineered as a straight tuck carton with a fifth-panel hang tab designed to securely attach the box to the bottle’s neck. Constructed from 24pt SBS, the packaging offered the strength and durability required to support the weight of the cooler, ensuring the hitchhiker remained intact throughout shipping and handling.

 

 

Printing & Coating

 

For additional promotional purposes, the hitchhiker was printed using four-color process. An overall gloss coating was applied for a sleek, polished look, while a spot dull varnish provided subtle contrast, accentuating specific details in the design. This combination of finishes elevated the overall presentation, reinforcing Jim Beam’s premium image.

Conclusion

 

This smart packaging solution allowed Jim Beam to include a substantial promotional item without significantly increasing the footprint of their packaging. The compact design takes up roughly the same space as the bottle alone—both in transit and on the shelf—yet adds considerable value to their product and enhances the consumer experience.

By combining strategic design, durable construction, and expert printing, we helped Jim Beam captivate consumers and drive sales in a competitive market.

Planning a limited-edition release or seasonal gift promo? Let’s design packaging that grabs attention and leaves a lasting impression. Get in touch with us today.

 

Hornitos Tequila Folding Carton Gift Packaging

Hornitos Tequila Folding Carton Gift Packaging

CASE STUDIES

Hornitos Tequila Folding Carton Gift Packaging

Overview

 

ADM partnered with Wynalda Packaging to develop a limited-edition margarita gift set for Hornitos Tequila, featuring a 750ml bottle of Plata tequila and a branded margarita glass.

As part of the Hornitos “Artist Edition” series, the packaging needed to showcase original artwork from a real artist while delivering durability, protection, and a premium shelf presence.

FEATURES

SPECIALTY COATINGS

FLUORESCENT INK

DURABILITY

Structure & Materials

 

To ensure strength and stability, we used 28pt SFI®-certified SBS, designed with a reinforced auto-lock bottom and double tuck closure. A gusset tuck with a tongue lock created clean, rolled edges and strong, secure corners.

Dual window cut-outs were added to highlight the tequila bottle and glass within. For internal protection, we engineered a custom insert made from 12pt SFI®-certified SBS laminated to E-flute, providing both product security and a premium appearance.

 

 

 

Printing & Finishing

 

The exterior of the box was printed with four-color process, plus a fluorescent yellow PMS color and Hornitos’ signature green PMS color for vibrant branding.

To elevate the tactile experience, we applied a combination of specialty coatings, including a dull varnish, spot gloss UV, and a reticulating coating, creating rich texture contrasts.

The interior insert was printed with a single PMS color and finished with a matte varnish for a clean, complementary look.

 

Conclusion

 

The final packaging successfully combined strength, style, and artistry, bringing the “Artist Edition” vision to life with a bold, gift-worthy presentation that celebrates both the product and the creative spirit behind it.

Planning a limited-edition release or seasonal gift promo? Let’s design packaging that grabs attention and leaves a lasting impression. 

Get in touch with us today.

 

 

Soft-Touch Boxes for Fab CBD

Soft-Touch Boxes for Fab CBD

CASE STUDIES

Soft-Touch Boxes For Fab CBD

The Challenge

 

Fab CBD, a premium hemp product brand, sought to enhance the sustainability of their packaging without compromising its luxurious look and feel. Their existing folding cartons were made from paperboard with a soft-touch laminate, which offered a rich texture and sophisticated aesthetic. However, the laminate contained plastic, reducing the cartons’ recyclability. Fab CBD needed a solution that would maintain the high-end finish that the soft-touch laminate provided while eliminating plastic to align with their sustainability goals.

FEATURES

SPECIALTY COATINGS

SUSTAINABILITY

DURABILITY

The Solution

 

Wynalda Packaging developed an innovative solution that met both the sustainability and aesthetic requirements. Instead of using soft-touch laminated paperboard, we transitioned to a standard 18pt SBS paperboard and used soft-touch coating to achieve the desired texture.

 

 

 

While a single layer of soft-touch coating provides a smooth, refined finish, it doesn’t quite match the rich, tactile feel of a laminate. To truly replicate that premium texture, we applied the soft-touch coating twice, using a second pass on press. The result was a remarkably luxurious tactile experience, virtually indistinguishable from a laminate, but without the plastic film.

To further enhance the sustainability of this project, we used an aqueous soft-touch coating rather than a UV coating. This water-based alternative reduces the emission of volatile organic compounds (VOCs) during drying and is more biodegradable and recyclable, making it a smarter, more eco-friendly choice.

We utilized this technique across Fab CBD’s product lines, ensuring consistency. Eachbox was printed with one of Fab CBD’s signature PMS colors, corresponding to the specific product line, and complemented with black accents for a polished and cohesive look.

 

 

 

The Results

 

The redesigned packaging successfully maintained Fab CBD’s premium aesthetic while reducing the environmental impact.

Want to explore innovative packaging solutions for your product? We are always happy to help. Speak with a packaging expert today!

Brushed Metallic Paper Boxes

Brushed Metallic Paper Boxes

CASE STUDIES

Brushed Metallic Folding Carton

Project Overview

Wynalda Packaging collaborated with IT Works, an industry-leading beauty and nutrition brand, to develop a premium secondary packaging solution for their body gel. The design was expertly crafted to replicate the sophisticated appearance of brushed metal, reflecting the luxury and quality of the product inside.

FEATURES

 

SPECIALTY COATINGS

 

METALLIC

 

DURABILITY

Structure and Material

 

We created an auto-bottom top tuck folding carton, tailored to securely hold the bottle of body gel. Constructed from 18pt MPE, the material’s shiny metallic base served as the perfect canvas for creating a high-end, brushed metal look.

 

 

 

Brushed Metal Effect

To achieve the desired “brushed metal” effect, we employed an innovative combination of two specialty coatings: reticulating varnish and dull varnish. The reticulating varnish provided a subtle texture in specific areas, creating contrast with the smoother finish of the dull varnish applied to the rest of the surface. This interplay of textures brought depth and realism to the metallic base, producing a stunning brushed metal effect that captivates attention and exudes elegance.

 

Printing

 

The box’s design was intentionally minimalistic to highlight the luxurious brushed metal finish. We applied two hits of white ink to mask the metallic sheen in the areas where the text and design elements were then printed using crisp black ink. This approach allowed the brushed metal effect to take center stage, reinforcing the product’s premium positioning.

 

 

 

 

Conclusion

 

This project merges innovative techniques and thoughtful design to create packaging that enhances brand identity and product perception. The brushed metallic folding carton for IT Works exemplifies sophistication, leaving a lasting impression on consumers while effectively communicating the product’s premium quality.

Want to explore innovative packaging solutions for your product? We are always happy to help. Speak with a packaging expert today!