Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Jul 20, 2026

CASE STUDIES

 

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

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Project Overview

The packaging for the EDJY Toenail Cutter was designed to reflect the product’s focus on quality, functionality, and sustainability. By combining a premium rigid box structure with recycled materials and a minimalist visual design, the finished package delivers an elevated unboxing experience while reinforcing the brand’s eco-conscious positioning.

FEATURES

SUSTAINABILITY

SPECIALTY COATINGS

PAPERBOARD INSERT

OUR CAPABILITIES

Premium Rigid Box Construction

 

The package features a two-piece telescoping rigid box that provides durability and a high-end presentation. Constructed with recycled chipboard and wrapped with recycled paper, the box offers the strength and protection expected from rigid packaging while incorporating more sustainable materials. To improve usability, the lid includes integrated thumb notches that make opening the package easy and intuitive.

Product Protection & Presentation

 

Inside the box, a straight-tuck SBS insert with press-in cutouts holds the toenail cutter in place. The insert keeps the product centered and protected during shipping and handling while creating a clean, organized presentation when the package is opened. The simple, unprinted insert design complements the minimalist aesthetic of the overall package while ensuring the product remains the focal point.

Sustainable Material Choices

 

Sustainability was a key consideration throughout the packaging design. The use of recycled chipboard, kraft paper wrap, and a paperboard insert provide a 100% paper-based solution, while maintaining a premium appearance. The mono-material design helps maximize recyclability and is widely accepted in curbside recycling streams.

Minimalist Printing & Coating

 

The outer wrap features a minimal design printed using four-color process printing. Since the paperboard wrap is Kraft brown, we also printed two layers of white under the product image to provide brighter, more vibrant colors. Rather than covering the entire wrap with graphics, the design intentionally leaves much of the recycled paper exposed, allowing the natural texture to remain visible. This reinforces the package’s sustainable character and helps reduce overall ink usage.

A soft-touch coating is applied over the entire wrap to protect the printed graphics and provide a premium feel, while preserving the natural look of the paper. 

 

Results

 

The finished package successfully balances premium presentation with environmental responsibility. Through thoughtful material selection, minimalist graphics, and functional structural design, the EDJY Toenail Cutter rigid box creates a distinctive unboxing experience that aligns with the brand’s values while providing the protection and shelf appeal expected from a premium product.

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Dr. Squatch Discovery Pack Cologne Packaging

Dr. Squatch Discovery Pack Cologne Packaging

Apr 9, 2026

CASE STUDIES

 

Dr. Squatch Discovery Pack Cologne Packaging

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Project Overview

 

Dr. Squatch, a fast-growing men’s personal care brand known for its rugged, natural aesthetic, required a premium packaging solution for their new Cologne Discovery Pack, designed to hold either three or five sample-size bottles of their Natural Cologne scents.

The packaging needed to deliver a high-end brand experience while aligning with the company’s sustainability values and aggressive product launch schedule. In addition to aesthetics, the project required tight coordination between design, manufacturing, and supply chain teams to ensure reliable execution ahead of the holiday selling season.

The brand required packaging that:

  • Utilized eco-friendly and responsibly sourced materials
  • Was produced by a domestic manufacturing partner to reduce risk and improve speed-to-market
  • Coordinated manufacturing within a timeline for a national holiday product launch
  • Maintained the premium look, feel, and brand consistency of their existing product line
  • Provided structural integrity to protect glass bottle during shipping and handling

Wynalda delivered a thoughtfully engineered packaging solution that combined sustainable materials with advanced manufacturing techniques, and precise structural design. The final package securely houses each bottle while creating an engaging unboxing experience that reflects that brand’s rugged, natural identity and supports efficient, scalable production.

FEATURES

CUSTOM MOLDED PULP

HOT FOIL STAMPING

EMBOSSING

OUR CAPABILITIES

Rigid Box

The outer package is a two-piece telescoping rigid box with an integrated platform, designed to align visually with Dr. Squatch’s existing packaging portfolio. It is constructed with 60 pt W1S recycled chipboard, providing the rigidity and durability required to protect fragile glass bottle throughout distribution and fulfillment. The 80# text wrap is printed on Wynalda Packaging’s Landa S11 Digital Offset Press, achieving six custom colors, and coated with a dull varnish for a refined, matte finish.

 

Embossing to Mimic Stock Texture

To maintain visual consistency with Dr. Squatch’s established packaging, the wrap material needed to replicate a specific textured surface used across their product line. Because a domestically sourced paper stock with that exact texture was not available within the required timeline, Wynalda’s team developed a process to emboss the entire sheet, recreating the desired texture while maintaining production efficiency and domestic sourcing requirements.

Hot Foil Stamping

After embossing, the wrap was hot foil stamped with design elements featuring fine lines and intricate details. Applying foil over a textured surface required precise control of pressure, temperature, and dwell time to ensure consistent adhesion and sharp visual detail.

“Throughout the project, we closely monitored the depth and consistency of the embossed texture to ensure it met both visual and tactile expectations. In addition, the customer required fine type foil stamping over the textured surface. This presented a unique challenge, as we needed to ensure proper foil adhesion on the embossed sheet while still maintaining crisp detail and the level of brilliance the customer expected.”

– Charles, Die Cutting & Stamping Manager

 

Molded Pulp Insert

Inside the box, a custom molded pulp tray securely holds the cologne bottles. Made from 20% recycled material, incorporating scrap solid bleached sulfate (SBS) generated from Wynalda’s own folding carton manufacturing process.  This closed-loop approach reduces material waste while supporting sustainability goals.

Structural Design Process

During the development process, Wynalda’s engineering team created and sent several iterations of 3D-printed samples to be tested for product fit and presentation. Once the structure of the tray was finalized, the team produced prototypes for a transportation study to ensure durability and performance.

Pulp Tray Masks Provide Versatility

To minimize tooling and production costs, Wynalda designed a single universal molded pulp tray that could be used for both the 3-bottle and 5-bottle discovery packs. We developed two different SBS masks for the pulp trays: one exposing all five cavities, and one exposing only three. The masks are printed with four-color process plus two custom colors and finished with dull varnish. They are then die-cut and glued to the molded pulp trays.

 

The Result

The final package successfully balanced sustainability, structural performance, and premium branding. The textured rigid box, detailed foil stamping, and molded pulp insert work together to create a high-end presentation with eco-conscious materials. The packaging met Dr. Squatch’s holiday launch timeline, delivered the brand experience they were looking for, and provided the flexibility needed for multiple product configurations.

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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.

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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!

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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!

 

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