Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Feb 5, 2026

CASE STUDIES

 

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

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Project Overview

Adrian Costa, a new fragrance brand launched in October 2025 in partnership with Perfumania, set out to create packaging with an elevated, luxury look and feel. 

While the brand recognized the perceived value of and premium feel of rigid boxes, the challenge was to deliver that experience using responsible, paper-based materials throughout.

FEATURES

SPECIALTY COATINGS

COLD FOIL & HOT FOIL

MOLDED PULP INSERT

OUR CAPABILITIES

Rigid Box

The rigid box is constructed from 60pt recycled chipboard (W1S) and wrapped in 80# white text, with precision skived corners that deliver sharp, clean edges on the box’s exterior.

The lid is printed with four-color process plus a custom PMS red and finished with a soft-touch coating. Cold foil was applied inline during printing and overprinted to create a custom foil tone, creating a subtle metallic sheen across the background. Select design elements were further enhanced with post-press hot foil stamping, adding depth and a rich, reflective contrast.

The base is printed in the custom PMS red and finished with a soft-touch coating, completing a cohesive, premium presentation.

Advanced rigid box equipment forms lids and bases simultaneously and joins them inline with robotic automation, ensuring tight tolerances, consistency, and production efficiency.

 

Molded Pulp Insert

The molded pulp insert is pressed to an ultra-smooth, premium finish with a 1mm wall thickness, providing strength and protection for the bottle.

The insert contains 20% recycled material, and production utilizes a recycled water tank to reduce overall water consumption.

Sustainability

The entire package is 100% paper-based, fully recyclable, and manufactured in the USA at Wynalda Packaging’s Michigan facility.

The Result

The final package delivers a refined unboxing experience that captures attention at retail while offering environmental responsibility.

By combining advanced manufacturing, premium finishes, and sustainable materials, this packaging solution reinforces Adrian Costa’s commitment to sustainability while elevating perceived retail value.

Looking to elevate your fragrance packaging? Connect with a packaging expert to explore premium, sustainable solutions tailored to your brand.

Case Studies

Don Julio’s 1942 Tequila Gift Box

Don Julio’s 1942 Tequila Gift Box

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Cigarette-Style Perforated Boxes for AdvoCare

Cigarette-Style Perforated Boxes for AdvoCare

Cold Foil Boxes for Don Julio

Cold Foil Boxes for Don Julio

VIEW ALL CASE STUDIES

Molded Pulp Book-Style Packaging for EDJY

Molded Pulp Book-Style Packaging for EDJY

Sep 24, 2025

CASE STUDIES

 

Molded Pulp Book-Style Packaging for EDJY

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The Challenge

 

EDJY, a trailblazer in premium nail care products, introduced the first-ever single-blade nail cutter engineered for clean, precise cuts without crushing nails. Their commitment to innovation and exceptional user experience doesn’t stop at the product itself—it extends to every brand touchpoint, including their packaging.

EDJY desired a new packaging solution that:

 

  • Distinguishes EDJY from competitors with a design unlike anything on the market.
  • Holds the product securely while opening and closing seamlessly.
  • Provides a unique and engaging unboxing experience.
  • Reflects the premium nature of EDJY’s product.
  • Upholds EDJY’s sustainability standards.

FEATURES

RECYCLABLE

BIODEGRADABLE

EMBOSSING

OUR CAPABILITIES

Our Solution

 

Wynalda’s Design Team delivered a custom-engineered packaging system that checked every box, blending innovation, performance, and sustainability into a cohesive design.

 

 

 

Packaging Structure

Molded pulp trays are traditionally used as box inserts or clamshells, but Wynalda’s Design Team created an innovative hybrid packaging structure that integrates molded paper pulp with a book-style paperboard wrap. The molded pulp tray is affixed to the back panel of the wrap, which folds around the tray and seals, forming a self-contained unit that offers both presentation and protection. This design provides generous printable space on both the interior and exterior, maximizing branding and storytelling opportunities. During fulfillment, the package is securely closed using wafer seals, keeping the product safe while streamlining EDJY’s pack-out process.

Molded Paper Pulp Tray

Made from 100% virgin fiber, the tray is pressed to an ultra-smooth finish to convey a refined look and feel, while maintaining durability with a 0.8mm wall thickness. The custom-formed tray is fully recyclable and biodegradable, providing a sustainable alternative to the plastic clamshells commonly seen in personal care and beauty packaging. Each tray is wash-trimmed for clean, uniform edges. The manufacturing process for the molded pulp utilizes a recycled water tank system, reducing water consumption and environmental impact.

 

 

Paperboard Wrap

To elevate shelf appeal, and give the packaging a natural look, the wrap is crafted using 18pt KraftPak paperboard. It is printed with EDJY’s minimalistic design and coated with a dull varnish only on the printed elements, allowing the natural fiber texture of the paperboard to be emphasized. This approach reduces ink and coating use, enhances recyclability, and contributes to the packaging’s eco-minded aesthetic. To elevate the design further, the card is embossed, creating a striking, dimensional effect that makes the product image on the front truly stand out. 

The Result

 

The new packaging accomplishes every functional and branding goal, all while upholding EDJY’s sustainability standards.

100% Paper-Based Packaging: All components are biodegradable and recyclable within a single stream—no material separation required. 

50% Material Reduction: Compared to their previous rigid setup box design, the new packaging solution cuts material weight in half, from 0.10 lbs to 0.05 lbs, resulting in improved transportation logistics and a lower carbon footprint.

Cost-Effective, Domestic Solution: By eliminating the rigid box and transitioning to molded pulp and paperboard, EDJY reduced their packaging costs while still delivering a premium experience to their customers. All packaging manufacturing took place at Wynalda’s Michigan facility, using domestically sourced materials, aligning with EDJY’s commitment to American-made excellence.

 

 

 

Conclusion

 

EDJY’s packaging now mirrors the ingenuity of their product—luxurious, sustainable, and unmistakably original. It’s a compelling story in how eco-conscious materials and clever structural design can work together to create an impactful customer experience.

Need help transforming your packaging? Wynalda’s experts are ready to collaborate on your next big idea. Let’s talk!

Case Studies

Don Julio’s 1942 Tequila Gift Box

Don Julio’s 1942 Tequila Gift Box

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Cigarette-Style Perforated Boxes for AdvoCare

Cigarette-Style Perforated Boxes for AdvoCare

Cold Foil Boxes for Don Julio

Cold Foil Boxes for Don Julio

VIEW ALL CASE STUDIES

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

Don Julio’s 1942 Tequila Gift Box

Don Julio’s 1942 Tequila Gift Box

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Cigarette-Style Perforated Boxes for AdvoCare

Cigarette-Style Perforated Boxes for AdvoCare

Cold Foil Boxes for Don Julio

Cold Foil Boxes for Don Julio

VIEW ALL CASE STUDIES

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.

 

Case Studies

Don Julio’s 1942 Tequila Gift Box

Don Julio’s 1942 Tequila Gift Box

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Rigid Box + Molded Pulp Fragrance Packaging for Adrian Costa

Cigarette-Style Perforated Boxes for AdvoCare

Cigarette-Style Perforated Boxes for AdvoCare

Cold Foil Boxes for Don Julio

Cold Foil Boxes for Don Julio

VIEW ALL CASE STUDIES