Folding Carton DVD Sleeve

Folding Carton DVD Sleeve

CASE STUDIES

 

Folding Carton DVD Sleeve

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

 

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.

 

Plastic Folding Cartons

Plastic Folding Cartons

CASE STUDIES

 

Plastic Folding Cartons

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

 

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.

 

Box With Window & Magnetic Closure

Box With Window & Magnetic Closure

CASE STUDIES

 

Box With Window & Magnetic Closure

The Challenge

Goal Zero needed packaging that allowed consumers to view the solar recharger from multiple angles while still providing enough print space to highlight features, benefits, and instructions. The structural challenge: maximize product visibility without sacrificing space for critical information.

FEATURES

 

CUSTOM COLOR

WYNVIEW™ RIGID WINDOW

 

MAGNET CLOSURE

 

The Solution

Our design team developed a box with a Wynview™ waterfall window, a two-panel rigid window that lets consumers see both the front and side of the product without opening the box.

To expand print space, we incorporated a front-opening door. The outside featured bold graphics, while the inside provided ample room for detailed product information.

To ensure the door remained secure on retail shelves, we engineered a hidden magnetic closure. This kept the door neatly shut but allowed consumers to open it easily for a closer look.

The Result

The packaging struck the perfect balance between visibility, functionality, and design. The concept was so effective, Goal Zero decided to incorporate the design into the packaging for many of their product variations.

 

Rigid Box With Sleeve

Rigid Box With Sleeve

CASE STUDIES

 

Rigid Box With Sleeve

Project Overview

Training Mask produces a popular product in the fitness and training industry. Our job at Wynalda Packaging was to develop a more premium line look and feel of the packaging for the new 3.0 Elevation Training Mask. In doing so the 3.0 mask could be distinguished from the previous 2.0 Training Mask products on the store shelves.

Training Mask developed a new and improved 3.0 version of their product and wanted a premium package to go along with it. Additionally, Training Mask was hoping to create a package that could have future use.

The objective was to create a premium package that would have the look and feel of a superior product to that of the 2.0 packaging. The packaging also had to have the ability to function as a storage container when the mask was not in use.

FEATURES

 

METALIZED POLYESTER O-SLEEVE

SPOT RETICULATING COATING

 

EMBOSSING

 

Structural Design

For the latest Training Mask packaging, our team moved away from the traditional folding carton used in previous models and opted for a premium rigid lid-and-base design.

This approach not only elevated the unboxing experience but also created a durable storage container that could stand up to everyday use. To add flexibility across different mask sizes and colors, we developed a printed bellyband (or sleeve) that wraps around the box, allowing for customization while using the same rigid box for all variations, helping to control costs.

Packaging Enhancements

The bellyband was enhanced with bright silver metalized paper, reticulated UV coating and spot gloss UV coating. The final enhancement was to emboss the graphic of the mask on the front of the package to really give this packaging a premium shelf presence.

 

 

The Result

The structural and graphical designs that were developed for this product gave the premium look that Training Mask was trying to achieve, distinguishing it from their current product and the other products in the marketplace.