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.

Cold Foil Boxes for Don Julio

Cold Foil Boxes for Don Julio

CASE STUDIES

 

Cold Foil Boxes for Don Julio

Project Overview

ADM Group partnered with Wynalda Packaging to develop a premium secondary packaging solution for Don Julio’s iconic 750ml bottles of Tequila Reposado and Tequila Blanco.

The goal was to design a visually striking box that not only reflected the premium quality of the tequila but also aligned seamlessly with the branding of the bottle and label inside.

FEATURES

SPECIALTY COATINGS

WINDOW CUT-OUT

COLD FOIL

Structure & Materials

 

To deliver the strength and durability needed to support the bottle’s weight, we engineered a folding carton from 28pt SBS, featuring a reinforced auto-lock bottom structure and partitioned dust flaps to hold the bottle securely in place. A circle window cut-out allowed the elegant bottle design to remain visible, reinforcing shelf appeal and brand recognition.

Printing & Finishing

 

To complement the gold foil accents on the bottle’s label, we used cold foil printing to add a metallic sheen to key design elements on the box. The box was printed using four-color process plus a custom gold spot color over the foil to perfectly match the gold foil on the label. The box was finished with an overall matte varnish, providing a sophisticated look and feel.

Conclusion

 

The final result was a cohesive, eye-catching promotional package that elevated Don Julio’s brand while ensuring product protection and retail impact.

 

Custom Magnetic Closure Box With Waterfall Window

Custom Magnetic Closure Box With Waterfall Window

CASE STUDIES

 

Custom Magnetic Closure Box With Waterfall Window

Project Overview

 

Blue Force Gear, a leading manufacturer of lightweight, modular tactical gear, was looking to elevate the unboxing experience for their Trauma Kit. Previously packaged in a simple poly bag, the brand wanted a solution that offered stronger shelf presence, enhanced branding, and distinct packaging for each SKU.

To help Blue Force Gear meet these goals, Wynalda Packaging developed a premium straight tuck carton made of 18pt SBS.

FEATURES

SPECIALTY COATINGS

WATERFALL WINDOW

MAGNETIC CLOSURE DOOR

Waterfall Window

 

This carton featured a two-panel waterfall window to showcase the pouch color, as the kit is available in multiple colors. Using 7mm APET, the window was die cut and applied using pick-and-place technology to achieve the waterfall effect.

Magnetic Closure Door

 

Since much of the front panel space was occupied by the window, we added a door with magnetic closure, creating extra real estate for messaging and product details while maintaining product visibility.

Custom Hang Tab

 

For retail versatility, we added a custom-designed injection-molded hang tab.

 

 

Printing & Coating

 

The carton was printed using four-color process with the addition of Blue Force Gear’s signature PMS blue. A soft-touch coating added a sleek, matte texture, while spot gloss UV created eye-catching contrast on key design elements.

SKU Differentiation

 

To accommodate product differentiation, the contents of each SKU were printed directly on the packaging. For their customizable Trauma Kit SKU, a blank space was reserved on the back for a label detailing the customer-selected contents.

 

 

Conclusion

 

This solution delivered a substantial upgrade in both form and function, improving brand perception, enhancing SKU distinction, and offering an engaging unboxing experience that reflects the premium nature of Blue Force Gear’s products.

Premium Spirits Packaging for Campari and Aperol

Premium Spirits Packaging for Campari and Aperol

CASE STUDIES

 

Premium Spirits Packaging for Campari & Aperol

Project Overview

 

Wynalda Packaging partnered with AMD Group to create promotional packaging solutions for two iconic Italian liqueur brands: Aperol & Campari. 

Designed to capture attention on crowded retail shelves, the packages were each crafted to hold a bottle of the liqueur along with cocktail accessories. The Aperol bottle was paired with an Aperol Spritz glass and the Campari bottle paired with a Negroni glass and mixing spoon.

FEATURES

SPECIALTY COATINGS

WINDOWING

THERMOFORMED TRAYS

Structure & Material

 

We designed folding cartons for each brand, both featuring an auto-lock bottom and double tuck closure, with the outer tuck using a gusset structure and tongue lock for sturdier corners and secure sealing. Constructed from 28pt SBS, the carton delivered the strength necessary to support the weight of the bottles and glasses. 

Window & Thermoformed Tray

 

A large window on the front of both boxes showcased the bottle and accessories, which were securely nestled in a custom thermoformed tray. 

Printing & Coating

 

Both cartons were printed using four-color process plus Campari’s signature PMS red and Aperol’s signature PMS orange. Given the visibility of the interiors through the large windows and clear thermoformed trays, both sides of the paperboard were printed for a seamless and cohesive look. The packages were coated with a dull varnish for a sophisticated matte look, and spot gloss was strategically applied to key design elements, adding contrast and visual interest.

 

 

Conclusion

 

By showcasing the bottles and accessories through a cohesive design, we enhanced Campari’s and Aperol’s retail presence and created memorable unboxing experiences for their customers. The thoughtful construction and high-quality printing and finishes ensured the packaging not only stood out on shelves but also reflected the elegance of each brand.

Special Edition Cider Bottle Carriers

Special Edition Cider Bottle Carriers

CASE STUDIES

 

Special Edition Cider Bottle Carriers

Project Overview

 

When a large retailer challenged Vander Mill, an artisan cidery, to bring something distinctive to market, they saw an opportunity to make a bold impression with their packaging.

Vander Mill’s idea was to create a standout special edition of their hard cider, packaged in bottles reminiscent of champagne, rather than the traditional 12 oz cider bottles. Vander Mill aimed to differentiate its product through eye-catching packaging that would attract attention on retail shelves. To complete this vision, Vander Mill needed a custom four-pack carrier to hold these uniquely shaped bottles.

FEATURES

SPECIALTY COATINGS

COLD FOIL

COLOR MATCHING

Structure & Material

 

Wynalda Packaging developed a custom die line to accommodate the specific dimensions of the champagne-style bottles. For material, we used our wet strength beverage board, an 18 pt CNK, which provides durability.

 

 

 

Printing & Coating

 

The carrier was printed with a sleek black background, white text, and two custom green PMS colors for a minimalistic yet elegant aesthetic. To achieve a high-end appearance, we used cold foil printing on select design elements, which added a metallic effect to the carrier. The carrier was finished with a dull varnish, with spot gloss on the foiled elements to enhance the shine and add a layer of protection.

Color Matching

Originally, their green PMS color was printed over both the foil and the black background, but this caused a very noticeable variation in the green color between the two surfaces. To ensure consistency across foiled and non-foiled sections, we made precise color adjustments resulting in two different custom green inks, ultimately achieving a seamless and cohesive look.

 

 

Conclusion

 

The final design provided a unique, visually appealing carrier that made the product stand out on the shelf. The special edition packaging not only fulfilled the retailer’s call for innovation, but also gave Vander Mill a distinctive edge in the competitive cider market.

Ready to elevate your beverage brand with custom bottle or can carriers designed to stand out? Contact us today or visit our WP Beverage Carriers site to discover our full capabilities.