NuLeaf Custom CBD Boxes

NuLeaf Custom CBD Boxes

Oct 18, 2024

CASE STUDIES

 

NuLeaf Custom CBD Boxes

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Project Overview

 

Wynalda partnered with NuLeaf, an organic CBD and hemp product manufacturer, to provide custom CBD boxes for their oils, balms, and softgels. We developed eight different seal-end folding carton designs, all constructed from FSC®-certified 20pt SBS (FSC® C149826).

 

FEATURES

EMBOSSING

SPECIALTY COATINGS

INSIDE PRINT

OUR CAPABILITIES

Inside Dividers

To hold the various sizes of products in place, many of these box designs incorporated inside dividers. Some of the cartons were designed so that when the box is erected, the dividers are automatically erected as well. Other designs required additional folding in order to accommodate the specific shape of the product.

Color Management

Each of the eight box designs has seven different color variations, indicating the type of product that it contains. For instance, their CBD products are green, their CBN products are purple, and their CBG products are yellow. All seven of these variations use custom PMS colors, which Wynalda produces and manages to insure color consistency and color quality across runs.

 

 

Inside Print

One of the defining features of these boxes is the bright inside print. The inside of each box is printed with a solid layer of that product’s corresponding color, adding vibrancy to the packaging. This design choice enhances the unboxing experience, elevates the perceived quality of the product, and reinforces NuLeaf’s branding.

 

Finishes and Embellishments

These boxes are all finished with a soft touch coating and spot gloss to give them a premium look and feel. Embossing is added to certain design elements to make them pop and enhance the tactile appeal of the packaging.

Cost Savings

These boxes are all finished with a soft touch coating and spot gloss to give them a premium look and feel. Embossing is added to certain design elements to make them pop and enhance the tactile appeal of the packaging.

 

 

Conclusion

NuLeaf has been very happy with their packaging, and has greatly benefitted from the cost savings that Wynalda is able to provide, leading to a productive partnership.

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

 

Case Studies

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Don Julio Custom Box Sleeves

Don Julio Custom Box Sleeves

Sep 10, 2024

CASE STUDIES

 

Don Julio Custom Box Sleeves

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Project Overview

 

Don Julio sought to enhance their 1942 tequila bottles for the holiday season with elegant custom box sleeves, creating a special edition look perfect for gifting. Wynalda collaborated with ADM Group to develop three distinctive sleeve designs, each bearing festive messages: “Happy Holidays,” “Congratulations,” and “Happy New Year.”

 

FEATURES

EMBOSSING

FOIL STAMPING

DURABILITY

OUR CAPABILITIES

Structure & Materials

We designed a tall, slim o-sleeve tailored to fit around the slender boxes of the tequila bottles. We selected a 24pt SUS board for its durability and premium look and feel.

Printing & Coating

The sleeves were printed using two hits of a custom brown ink, ensuring rich, consistent color. To protect the sleeves from rubbing, we applied an overall gloss coating, followed by a dull varnish. By using this combination of coatings, we were able to achieve much better rub test results, while maintaining a luxurious appearance and tactile quality.

 

 

 

Embellishments

This project incorporated some complex, yet rewarding embellishments. We used hot foil to add the text and logo to the sleeve, followed by sculpted embossing to create a striking 3D effect. The challenging aspect of this design was that the embossed elements ran across the scores of the sleeve. In order to create the desired effect without affecting the crease lines, we carefully tapered the embossing at the scores.

 

Results

The holiday sleeves transformed the Don Julio 1942 tequila bottles into exquisite, gift-ready pieces. The combination of custom ink, sophisticated coatings, gold foil, and meticulous embossing created a stunning visual impact, enhancing the premium feel of the product.

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.

 

Case Studies

Disney Lion King Collector’s Edition Rigid Box Set

Disney Lion King Collector’s Edition Rigid Box Set

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Knob Creek Whiskey Rigid Gift Packaging

Cosmetics Box Packaging

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Microtech Knives Telescoping Rigid Boxes

Microtech Knives Telescoping Rigid Boxes

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Custom Molded Pulp Trays For Chocolate Bunnies

Custom Molded Pulp Trays For Chocolate Bunnies

Jul 17, 2024

CASE STUDIES

 

Custom Molded Pulp Trays For Chocolate Bunnies

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The Challenge

 

A large chocolate company had been facing a significant challenge with their direct-to-consumer chocolate bunnies一their ecommerce products were frequently arriving cracked. Their initial packaging solution involved wrapping the bunnies in bubble wrap, which proved insufficient in protecting the delicate products during transit. This not only led to customer dissatisfaction but also increased the cost due to replacements and returns. 

Recognizing the need for a more effective and sustainable solution, they sought a packaging method that could provide protection for their product while aligning with their commitment to environmental sustainability.

FEATURES

BIODEGRADABLE

RECYCLED MATERIAL

DURABILITY

OUR CAPABILITIES

The Solution

Wynalda Packaging stepped in to solve this problem by designing a custom molded pulp tray for the chocolate bunnies. This innovative packaging solution involved creating a tray that snugly fit around the bunny, ensuring that no part of the product was more than 3mm away from the surface of the tray. This close fit provided optimal protection against impacts and vibrations during shipping.

Wynalda Packaging provided samples for drop testing, allowing them to work together to refine the packaging and create a product with maximized protective capabilities. The molded pulp, made from up to 100% recycled materials and fully biodegradable, not only offered exceptional protection but also aligned perfectly with the company’s sustainability goals.

 

 

The Results

The implementation of the custom molded pulp tray drastically reduced the incidence of cracking during transit, significantly improving customer satisfaction and reducing the costs associated with product damage and returns.

This innovative packaging solution positioned this company as a leader in the industry, being one of the first to adopt molded pulp for shipping delicate products directly to consumers.

This solution was so effective that they are now expanding the use of this packaging technique to some of their other products, further enhancing their reputation for both quality and sustainability.

By adopting this advanced and eco-friendly packaging solution, they provided a compelling example of how companies can innovate to meet both environmental and operational goals. 

Talk with a packaging expert to learn how you can use innovative packaging to protect your products and the planet.

Case Studies

Disney Lion King Collector’s Edition Rigid Box Set

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Knob Creek Whiskey Rigid Gift Packaging

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Folding Carton DVD Sleeve

Folding Carton DVD Sleeve

Dec 27, 2018

CASE STUDIES

 

Folding Carton DVD Sleeve

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The Challenge

Lionsgate reached out to Wynalda Packaging for help in designing the DVD sleeve for the 30th Anniversary of Shark Week, the television event.

Lionsgate’s goal was to create a special edition package to stand out on the shelf by incorporating a beach and ocean theme.  Lionsgate wanted the consumer to feel that they were part of the action; as if they were on the beach.

The challenge for our design team was to design a package that would give the look and feel of being on a beach. Our graphic and structural design team was determined to make the package feel like you were touching the sand on the beach.

FEATURES

 

4-COLOR PRINTING

SPOT RETICULATING COATING

 

SCULPTURED EMBOSS

OUR CAPABILITIES

 

The Solution

The idea of using specialty coatings and sculpted embossing was the answer to this challenge.  Using a reticulated (textured) coating on the sand areas gave the package the feel of real sand. Additionally, using high gloss UV coating on the ocean and life ring made the sand area stand out even more. These specialty coatings draw a consumers attention to the rough and gritty sand.

The final touch used to bring the visual to life was sculptured embossing. The sculptured embossing of the key elements such as the shark, jaws and seal as well as the minor elements like the small castle, sand bucket and shovels and the life ring, made the images in the sand come to life as if they were just carved out of the sand.

The Result

The final result was a package with a very unique visual when it was on the shelf, but an even bigger sensory response when it was held. The story of Shark Week’s 30 years of Jaw-Dropping Discovery came to life before it was ever unpackaged and placed into the DVD player.

 

Case Studies

Disney Lion King Collector’s Edition Rigid Box Set

Disney Lion King Collector’s Edition Rigid Box Set

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Knob Creek Whiskey Rigid Gift Packaging

Cosmetics Box Packaging

Cosmetics Box Packaging

Microtech Knives Telescoping Rigid Boxes

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Plastic Folding Cartons

Plastic Folding Cartons

Dec 27, 2018

CASE STUDIES

 

Plastic Folding Cartons

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The Challenge

 

Fourth Arrow Brands, the creator of Wyndscent technology, partnered with Conquest Scents to launch ScentFIRE—a first-of-its-kind product that converts hunting scents into timed vapor releases. The packaging needed to showcase the innovative power unit while maintaining ample print space for features and benefits.

Key challenges included:

  • Securing the heavy device in place without rotation, ensuring branding and controls stayed visible.
  • Designing a durable hanging solution for retail displays, as traditional hangtags couldn’t support the weight.
  • Protecting ancillary components while highlighting the main device.
  • Choosing materials that could withstand the variable conditions of trade shows and outdoor expos.

FEATURES

 

PET CONSTRUCTION

THERMOFORMED TRAY

 

INJECTION MOLDED HANGER

OUR CAPABILITIES

 

The Solution

Our design team engineered a custom PET folding carton with a thermoformed tray to lock the power unit in place. This ensured the device always faced forward, with branding and controls visible on the shelf. The tray also secured ancillary components, keeping them concealed yet protected.

To handle the product’s weight, we developed a custom injection-molded hang tab, providing the strength needed for reliable retail display. PET plastic proved the ideal choice—delivering durability, clear product visibility, and high-quality full-color printing suited for both indoor and outdoor environments.

The Result

The final packaging balanced durability, visibility, and communication, helping ScentFIRE make a strong impression at retail and industry expos. Fourth Arrow and Conquest Scents were thrilled with the results and have since expanded their partnership with Wynalda Packaging for additional accessories.

 

Case Studies

Disney Lion King Collector’s Edition Rigid Box Set

Disney Lion King Collector’s Edition Rigid Box Set

Knob Creek Whiskey Rigid Gift Packaging

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Cosmetics Box Packaging

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