DNA Collection Kit Packaging for FamilyTreeDNA

DNA Collection Kit Packaging for FamilyTreeDNA

CASE STUDIES

 

DNA Collection Kit Packaging for FamilyTreeDNA

Project Overview

FamilyTreeDNA tasked Wynalda Packaging with designing and producing packaging for a DNA Collection Kit. The packaging needed to protect and hold the kit’s contents securely while presenting a high-quality, professional appearance and seamless unboxing experience.

FEATURES

SUSTAINABILITY

SPECIALTY COATINGS

PAPERBOARD INSERT

Structural Design

 

We designed a folding carton package consisting of three elements: a tray, an outer sleeve that slides over the tray, and an insert to hold the product in place inside the tray. We also incorporated a locking mechanism into the tray to stop it from sliding all the way out of the sleeve. All three elements were crafted from 28 pt SBS, providing a clean, white printing surface and sturdy structure and support for the kit’s contents.

Printing & Coating

 

The sleeve was printed with CMYK plus a custom PMS orange, and the entire tray was printed with that same PMS orange. The insert, as well as the background of the sleeve, was left unprinted, allowing the white stock to show through.

To achieve a premium look and feel, we applied a soft-touch coating on the sleeve with spot gloss UV added to enhance specific design elements. The tray was finished with a flood gloss UV coating, and the insert was finished with a flood soft-touch coating. We used a Cyrel plate to achieve precise spot gloss registration on the intricate details of the design.

Conclusion

 

The final product was a secure and aesthetically pleasing DNA Collection Kit that provided a premium look and feel. The combination of high-quality materials, specialty coatings, and meticulous printing ensured a professional, refined look that enhanced the unboxing experience and reflected the brand’s dedication to quality.

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Sustainable, Anti-Theft Packaging Redesign for PopSockets

CASE STUDIES

 

Sustainable, Anti-Theft Packaging Redesign for PopSockets 

The Challenge

PopSockets needed a new packaging solution for its PopGrips with Swappable Tops. Each package contained two interlocking components—a base and a top—and had to allow shoppers to see and interact with the product while it remained inside the package.

At the time, the product was packaged using a thermoformed plastic insert inside a folding carton. While this design provided a hands-on customer experience, it also created a significant retail challenge: the product could be removed too easily, leading to theft and product loss.

At the same time, PopSockets was working to reduce the environmental impact of its packaging by eliminating plastic components wherever possible.

The challenge was to create a packaging solution that improved security, supported sustainability goals, and still allowed customers to engage with the product before purchase.

FEATURES

COLD FOIL

SPECIALTY COATINGS

EMBOSSING

Structural Design

Wynalda Packaging developed a new structure built around a paperboard retention card that the PopGrip securely screws into. The card is enclosed within a windowed envelope-style folding carton that allows customers to see and touch the product while preventing it from being removed without damaging the package.

  

Sustainability

The redesigned package was manufactured using 100% recycled paperboard and was fully recyclable and FSC®-certified (FSC® C149826). By replacing the thermoformed plastic insert with a paperboard-based solution, PopSockets was able to eliminate plastic from the package and move closer to its sustainability objectives without sacrificing functionality or shelf appeal.

Printing

The project coincided with a broader brand refresh, requiring exceptional color accuracy across a wide range of SKUs.

Wynalda Packaging produced seven custom spot colors in-house, including five fluorescent inks, to achieve the vibrant appearance PopSockets was looking for. In addition, the packaging program included numerous licensed and co-branded product lines, including collaborations with Coca-Cola, Harry Potter, Vera Bradley, Peanuts, Marvel, Star Wars, and TikTok.

Maintaining consistent color reproduction across multiple brands, graphics, and product variations required careful color management throughout production.

 

Finishing & Embellishments

To enhance shelf impact, the packaging incorporated several premium finishing techniques.

A reticulating coating combined with spot gloss UV created visual contrast and tactile texture.

Cold foil was applied inline during printing to add metallic effects while maintaining production efficiency.

Select design elements were further enhanced through embossing, adding depth and dimension to the finished package.

Converting & Assembly

The package design required a specialized gluing and assembly process to achieve the desired structure at production speeds.

Custom converting techniques were used to accurately form the package, including a unique gluing sequence that allowed the structure to be assembled efficiently while securely retaining the product. Double-sided tape was incorporated to provide a reliable closure and ensure package integrity throughout distribution and retail handling.

 

The Results

The redesigned packaging successfully addressed all of PopSockets’ primary objectives: reducing theft, eliminating plastic, and maintaining hands-on product engagement.

The new structure made product removal significantly more difficult without damaging the package, helping reduce theft in retail environments.

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Secondary Packaging for Maker’s Mark Wood Finishing City Series

CASE STUDIES

 

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Project Overview

ADM partnered with Wynalda Packaging to develop secondary packaging for the Maker’s Mark Wood Finishing City Series — exclusive New York and Sydney editions featuring cask-strength, locally inspired bourbons available only in their respective airports. The packaging was designed to reflect the premium nature of the collection while creating strong shelf presence for travelers seeking a unique, destination-specific offering.

FEATURES

CUSTOM PANTONE COLORS

DULL VARNISH

EMBOSSING

Structure & Materials

The package is constructed from 24pt SBS, featuring an auto-bottom folding carton with a gusset-tuck top and reinforced side walls to provide added strength and durability for the bottle during transportation and retail display.

 

Printing & Finishing

To maintain consistency with both the bottle design and the Maker’s Mark brand identity, the carton is printed using three Pantone colors: Maker’s Mark signature red, a custom black, and a custom cream background carefully color-matched to the bottle label. To reinforce the natural, wood-inspired aesthetic of the Wood Finishing Series, black graphics were used to create a tree-ring pattern across the top of the box, along with fine fiber detailing throughout the background to emulate the look of textured paper. A dull varnish was applied to enhance the organic appearance and provide a refined matte finish.

Embossing

Selective embossing was added to key text elements on the front panel to create depth, dimension, and a tactile, premium feel that elevates the overall presentation.

 

Conclusion

This packaging solution combines durable structure, refined print execution, and thoughtful finishing details to support the premium positioning of the Maker’s Mark Wood Finishing City Series. The result is a distinctive retail package that captures the craftsmanship and exclusivity of the collection while delivering a polished consumer experience.

Don Julio’s 1942 Tequila Gift Box

Don Julio’s 1942 Tequila Gift Box

CASE STUDIES

 

Don Julio’s 1942 Tequila Gift Box

Project Overview

ADM partnered with Wynalda Packaging to develop premium secondary packaging for Don Julio’s iconic 1942 tequila bottle as part of its 2025 holiday program. The goal was to create a visually striking carton that elevated shelf presence and positioned the tequila as a festive gift.

FEATURES

SPECIALTY COATINGS

COLD FOIL

DEBOSSING

Structure & Materials

The carton was produced using 28pt SBS C1S and engineered with an auto-lock bottom and tuck-top closure. This structure delivers exceptional strength and stability while supporting efficient assembly.

 

Printing & Cold Foil

To achieve a refined metallic aesthetic, cold foil was applied to the top half of the carton, then overprinted with a custom gold PMS color and finished with spot gloss. This layered approach created a foil effect that perfectly aligns with Don Julio’s signature branding. The bottom half of the carton was printed in Don Julio’s iconic brown using four-color process and finished with a dull varnish, delivering richness, contrast, and depth.

 

Debossing

Across the top half of the carton, a debossed groove pattern was incorporated to add visual and tactile interest. Extending across the box folds, the deboss required meticulous attention to detail and precise registration. Accentuated by the cold foil and spot gloss, the detail reinforces the carton’s luxurious look and feel.

 

Result

The finished package delivers a sophisticated yet festive, gift-worthy presentation that commands attention at retail while staying true to Don Julio’s iconic brand identity.

Cigarette-Style Perforated Boxes for AdvoCare

Cigarette-Style Perforated Boxes for AdvoCare

CASE STUDIES

 

Cigarette-Style Perforated Boxes for AdvoCare

Project Overview

AdvoCare, a premium dietary supplement brand, partnered with Wynalda to create retail packaging for their new powdered kombucha supplement, Harmony®.

The packaging had to securely hold 15 individual stick packs while delivering:

  • A convenient, user-friendly experience
  • A refined, high-end presentation
  • Strength and durability

FEATURES

SPECIALTY COATINGS

PERFORATION

CUSTOM SPOT COLORS

Cigarette-Style Perforated Box

 

To achieve these objectives, Wynalda Packaging designed a cigarette-style perforated box made from 24pt SBS. The design features an auto-lock bottom for added strength and fulfillment efficiencies, while a perforated flip-top lid allows consumers to store the box in their cupboard and easily remove one stick pack at a time. 

Inner Collar

 

To enhance the strength and maintain the box’s shape after opening, we added a three-panel inner collar that lines the front and sides of the box, forming an internal support wall that reinforces the structure and ensures a secure closure for the lid.

Printing & Coating

 

Color accuracy was critical for AdvoCare’s brand. The carton was printed using four PMS colors plus black, then finished with a soft-touch coating and spot gloss UV to achieve a refined, tactile finish.

 

 

The Result

 

The final result delivered on every objective, combining strength, aesthetic appeal, and functionality. AdvoCare was thrilled with the Harmony packaging and is now exploring the same design for other product lines.