Rigid Drawer Boxes With Layered Windows

Rigid Drawer Boxes With Layered Windows

Mar 28, 2025

CASE STUDIES

Rigid Drawer Boxes With Layered Windows

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Overview

 

In collaboration with Cinco Design, we developed a distinctive and engaging packaging solution for VSSL, a high quality outdoor gear brand.

The packaging was designed to hold a compact critical supplies kit, with a focus on both functionality and aesthetic appeal.

The solution consists of three components: an outer slip case, a rigid tray, and a cleverly engineered paperboard insert.

FEATURES

WINDOWING

SUSTAINABILITY

DURABILITY

OUR CAPABILITIES

Outer Slip Case and Paperboard Insert

 

The outer slip case is a tuck-top folding carton with an open bottom, allowing the rigid tray to slide inside.

What makes this packaging truly stand out is the series of layered cutouts incorporated into both the slip case and the paperboard insert. The front of the sleeve has a cutout revealing the insert beneath it, which features three additional layers, each with its own cutout. This layered design creates a striking illusion of multiple sleeves encasing the box, while offering product visibility.

To achieve this effect cost-effectively and sustainably, we folded a single piece of paperboard multiple times, forming layers. The result is a design that delivers depth, dimension, and both visual and tactile intrigue, while minimizing material usage and production costs.

 

 

Both the outer sleeve and the insert are crafted from 0.018 KraftPak, chosen for its strength and eco-friendly qualities.

The material is printed using four-color process, plus two hits of white ink, and finished with a dull varnish on the printed areas. To maintain a natural, earthy aesthetic, most of the KraftPak is intentionally left unprinted.

Rigid Tray

Inside the sleeve is a rigid tray, providing the package with essential structural integrity. Constructed from 0.042 kraft chipboard, the tray aligns with the natural, sustainable theme of the overall design. It is wrapped in 80# text paper, printed using four-color process and coated with a dull varnish for consistency across the entire package.

 

 

Conclusion

This packaging solution balances innovation, aesthetics, quality, and sustainability to create a visually striking and functional package that reflects VSSL’s brand identity.

Want to explore innovative packaging solutions for your product? We are always happy to help you brainstorm ideas and troubleshoot challenges. Speak with a packaging expert today!

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Disney Lion King Collector’s Edition Rigid Box Set

Disney Lion King Collector’s Edition Rigid Box Set

Mar 3, 2025

CASE STUDIES

Disney Lion King Collector’s Edition Rigid Box Set

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The Challenge

 

Disney approached Wynalda Packaging with a creative vision: to design a Lion King collector’s edition DVD set packaged inside a box that looks like a drum. This unique concept posed multiple challenges. The circular shape of the drum was not ideal for shipping and limited the amount of space available for branding or promotional content.

To address these issues, the drum would need additional outer packaging. Disney also envisioned the packaging as being part of the collector’s item, something fans would proudly display rather than discard after opening. Therefore, the outer packaging had to complement the drum design while being aesthetically pleasing enough for people to want to showcase.

FEATURES

EMBOSSING

HOT FOIL STAMPING

SPECIALTY COATINGS

OUR CAPABILITIES

The Solution

Wynalda’s design team crafted a stunning packaging solution that fulfilled all of Disney’s objectives. The packaging included an outer rigid box with a hinged door panel that opened to reveal the drum, which housed a paperboard disc booklet. To provide additional branding and promotion space, the entire set was wrapped in a paperboard belly band.

 

 

Carved Wood Effect

The outer rigid box was designed to look like carved wood. To recreate this effect, we wrapped the chipboard box in a sheet of paper that had been embossed across the entire surface.

Because of the large surface area, depth, and detail of the emboss, this process required significant pressure. Initially we tried embossing 100# C1S to wrap around the chipboard, but we found that it did not retain the desired level of detail after being wrapped.

To resolve this, we switched to 100# MPE, which held the embossing much more effectively, giving the box a rich texture. We then printed the MPE with a solid white layer to eliminate any shine, followed by four-color process to create the wood grain design, and finished it with a dull varnish.

The combination of deep embossing, printing, and coating resulted in a box that looked and felt like carved wood.

Disappearing Hinged Door

For a unique display experience, we designed a hinged door that could slide into the side of the box and disappear, perfectly showcasing the drum inside. This hidden door could be pulled back out using the attached ribbon tab.

To prevent the door from completely coming out of the box when sliding it out, we designed a paperboard locking mechanism for the door. Another ribbon was added to the inside of the box to make it easier to pull the drum out of the box.

The inside of the box was lined with 60pt black chipboard, forming a neck ring around the opening of the box, which allowed the door to be recessed and flush with the outside of the box. 

 

 

Drum-Shaped Box

To create the drum-shaped box, we wrapped 80# C1S around a chipboard cylinder. The drum was capped on both ends with uncoated kraft to replicate the leather ends of a traditional drum.

The top and bottom trays fit together so that they were flush with one another, creating a smooth surface.

The C1S was printed with four-color process, coated with a dull varnish, and embossed to give the drum strings a realistic texture.

Paperboard Booklet

Inside the drum, we developed a paperboard booklet that fanned out and held the eight discs from the Lion King Collector’s Edition.

This booklet could be fastened with velcro straps and was seated securely in a custom-designed foam insert wrapped in solid black paperboard and placed inside the bottom tray.

 

 

Belly Band 

Finally, to add more in-store branding and promotion, we added a printed paperboard belly band, finished with hot foil to add a bit of shine.

The Results

The Lion King Collector’s Edition packaging was a resounding success. Disney’s vision for a unique and display-worthy box was brought to life, with intricate details and materials that truly embodied the luxury and collectability they sought.

The drum-shaped box, combined with the clever outer packaging design, not only solved the shipping and branding issues but also elevated the product into a showpiece that fans could proudly display.

 

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Knob Creek Whiskey Rigid Gift Packaging

Knob Creek Whiskey Rigid Gift Packaging

Feb 10, 2025

CASE STUDIES

 

Knob Creek Whiskey Rigid Gift Packaging

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Overview

 

Knob Creek needed packaging for a new gift set, which included a bottle of their Kentucky Straight Bourbon Whiskey and two signature whiskey glasses.

The packaging needed to be durable enough to support the weight of these items while also allowing the contents to be displayed attractively.

FEATURES

WINDOWING

SUSTAINABILITY

DURABILITY

OUR CAPABILITIES

Structure & Materials

 

To meet these requirements, we collaborated with ADM Group to design a telescoping rigid box featuring three window cut-outs to showcase the products inside. Additionally, the box included a laminated corrugate insert to securely hold each item in place, preventing them from colliding during transport.

 

The rigid box was constructed from a 50pt kraft chipboard, wrapped in an 80lb label stock printed sheet for a premium finish. The insert was made from E flute laminated with 12pt SBS, ensuring both strength and a refined appearance. In alignment with Knob Creek’s commitment to sustainability, all materials used were FSC®-certified and recyclable. (FSC® C149826)

 

 

Printing & Coating

We produced two versions of this box. In 2023, we printed the box with a custom green color paired with a gold PMS color and four-color process printing.

The following year, we updated the design, replacing the custom green with a sleek custom black.

Both versions were coated with a dull varnish for a sophisticated matte finish, complemented by spot gloss on the gold elements to add a little bit of shine.

Results

 

The final packaging solution was both aesthetically pleasing and highly functional. The combination of durable materials, thoughtful design, custom colors, and specialty coatings ensured that the packaging not only protected and displayed the contents but also enhanced the overall brand experience.

Talk with a packaging expert to learn how you can optimize your product packaging for both aesthetics and functionality.

 

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Cosmetics Box Packaging

Cosmetics Box Packaging

Dec 18, 2024

CASE STUDIES

 

Cosmetics Box Packaging

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Overview

 

Farouk Systems, a company known for manufacturing high-quality professional hair care products, reached out to Wynalda Packaging for a solution to package their CHI Vibes Squad Goals Kit, consisting of three product bottles.

The goal was to create a secure, aesthetic box that would prevent the bottles from rattling and shifting during transport, ensuring a premium unboxing experience for customers.

FEATURES

SPECIALTY COATINGS

INTERNAL DIVIDERS

DURABILITY

OUR CAPABILITIES

Structure & Materials

To meet these needs, we designed a top tuck auto-bottom folding carton with a tongue lock, offering secure closure and stability.

To keep the bottles from moving inside the box, we incorporated a custom internal divider that precisely fit the dimensions of the product. This divider was integrated into the structure of the box, providing a snug fit that effectively eliminated any internal movement.

For durability and a high-quality appearance, we used 24 pt SBS paperboard.

 

 

Printing & Coating

The box was printed using four-color process, achieving a bright, colorful design that reflects the playful spirit of the CHI Vibes brand.

To enhance the visual and tactile appeal, we applied an overall dull varnish and added spot gloss to key design elements, giving the package a sophisticated, premium finish.

Results

The final packaging solution for the CHI Vibes Squad Goals Kit delivered both form and function. The custom internal divider kept the bottles securely in place, while the vivid printing and specialty finishes created an eye-catching package. All of these elements came together to provide a premium unboxing experience for Farouk’s customers.

Talk with a packaging expert to learn how we can help you can elevate your brand with unique, premium packaging.

 

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Microtech Knives Telescoping Rigid Boxes

Microtech Knives Telescoping Rigid Boxes

Nov 22, 2024

CASE STUDIES

 

Microtech Knives Telescoping Rigid Boxes

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The Challenge

 

 

Microtech Knives, a high-end manufacturer of premium knives, sought to upgrade their packaging from a simple corrugated hinged-lid box to something with a more premium look and feel that matched the high quality of their product. Their vision was to create packaging similar to “The Apple Box”.

FEATURES

METALIZED PAPERBOARD

DURABILITY

INVENTORY MANAGEMENT

OUR CAPABILITIES

The Solution

Our package designers rose to the challenge and developed a custom rigid box with skived corners made from solid black chipboard. We incorporated angled cuts into the sides of the lid to give it a more unique and sophisticated look.

The box was wrapped with MPE laminate, achieving a metallic effect without the need for foil stamping, thereby maintaining consistency with Microtech’s existing branding. 

The boxes were printed using four-color process plus two spot colors to achieve the dramatic gold and red metallic colors that represent the Microtech brand. The print was finished with a combination of dull varnish and spot gloss treatments.

 

 

After the initial production run, Microtech desired an even higher quality look. In response, our team converted the box exterior to a solid black Neenah stock with a MPE laminate, which eliminated the white cross section on the cut ends of the wrap material. The result was a flawless, sleek package that perfectly represented the unsurpassed quality that Microtech puts into every one of their knives.

Results

Microtech was thrilled with the end result of their new packaging and how it aligned with their expectations and represented their brand. Based on their supply chain needs, Microtech also decided to take advantage of Wynalda’s Vendor Managed Inventory (VMI) program. The program developed for Microtech’s specific needs, allows them to adjust which box SKUs are produced and available for immediate distribution. 

This project faced several challenges during the development phase, and required extreme attention to detail throughout the manufacturing process. Wynalda’s team of experts faced each challenge head on in order to ensure positive outcomes and exceed Microtech’s expectations.

Talk with a packaging expert to learn how we can help you can elevate your brand with unique, premium packaging.

 

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