Soft-Touch Boxes for Fab CBD

Soft-Touch Boxes for Fab CBD

May 29, 2025

CASE STUDIES

Soft-Touch Boxes For Fab CBD

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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

OUR CAPABILITIES

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!

Case Studies

Molded Pulp Book-Style Packaging for EDJY

Molded Pulp Book-Style Packaging for EDJY

Modular Rigid Box Packaging for TruDiagnostic

Modular Rigid Box Packaging for TruDiagnostic

Jim Beam Bottle Hitchhiker Packaging

Jim Beam Bottle Hitchhiker Packaging

Hornitos Tequila Folding Carton Gift Packaging

Hornitos Tequila Folding Carton Gift Packaging

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Brushed Metallic Paper Boxes

Brushed Metallic Paper Boxes

May 15, 2025

CASE STUDIES

Brushed Metallic Folding Carton

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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

OUR CAPABILITIES

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!

 

Case Studies

Molded Pulp Book-Style Packaging for EDJY

Molded Pulp Book-Style Packaging for EDJY

Modular Rigid Box Packaging for TruDiagnostic

Modular Rigid Box Packaging for TruDiagnostic

Jim Beam Bottle Hitchhiker Packaging

Jim Beam Bottle Hitchhiker Packaging

Hornitos Tequila Folding Carton Gift Packaging

Hornitos Tequila Folding Carton Gift Packaging

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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!

Case Studies

Molded Pulp Book-Style Packaging for EDJY

Molded Pulp Book-Style Packaging for EDJY

Modular Rigid Box Packaging for TruDiagnostic

Modular Rigid Box Packaging for TruDiagnostic

Jim Beam Bottle Hitchhiker Packaging

Jim Beam Bottle Hitchhiker Packaging

Hornitos Tequila Folding Carton Gift Packaging

Hornitos Tequila Folding Carton Gift Packaging

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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.

 

Case Studies

Molded Pulp Book-Style Packaging for EDJY

Molded Pulp Book-Style Packaging for EDJY

Modular Rigid Box Packaging for TruDiagnostic

Modular Rigid Box Packaging for TruDiagnostic

Jim Beam Bottle Hitchhiker Packaging

Jim Beam Bottle Hitchhiker Packaging

Hornitos Tequila Folding Carton Gift Packaging

Hornitos Tequila Folding Carton Gift Packaging

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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.

 

Case Studies

Molded Pulp Book-Style Packaging for EDJY

Molded Pulp Book-Style Packaging for EDJY

Modular Rigid Box Packaging for TruDiagnostic

Modular Rigid Box Packaging for TruDiagnostic

Jim Beam Bottle Hitchhiker Packaging

Jim Beam Bottle Hitchhiker Packaging

Hornitos Tequila Folding Carton Gift Packaging

Hornitos Tequila Folding Carton Gift Packaging

VIEW ALL CASE STUDIES