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.

FDA-Approved Pharmaceutical Packaging

FDA-Approved Pharmaceutical Packaging

CASE STUDIES

 

FDA-Approved Pharmaceutical Packaging

The Challenge

PharmaEssentia, a Taiwan-based pharmaceutical company, works to redefine the potential of proven therapies to enhance the health and quality of life for patients living with hematologic diseases. In 2017, they expanded into the U.S. market and began the rigorous process of obtaining FDA approval for their product. This process demanded production-quality printed packaging samples for each submission, and multiple revisions were expected. Therefore, PharmaEssentia relied heavily on Wynalda to quickly produce these samples to keep the approval process on track.

In addition to navigating the FDA’s requirements, PharmaEssentia aimed to redesign their product packaging for enhanced functionality and improved customer experience. The original packaging consisted of a simple reverse tuck carton and a paperboard insert. The insert lacked sturdiness and did not provide the desired unboxing experience, and the external design was minimalistic, featuring only a logo and black text. Since this packaging would be consumer-facing, PharmaEssentia sought to elevate the design with refined details to create a more positive user experience.

FEATURES

SPECIALTY COATINGS

METALIZED PAPERBOARD

THERMOFORMED TRAY

Our Solution

 

Wynalda began by replacing the paperboard insert with a thermoformed tray, significantly enhancing the syringe’s security and improving the overall customer experience. The trays are crafted from a 30 pt PETE medical blue material, which is 100% recyclable, and they are produced in an FDA-approved cleanroom. The cartons were sized to hold both the thermoform tray as well as a separate insert detailing the instructions for use.

 

 

 

To elevate the visual appeal of the packaging, Wynalda encouraged the use of 18pt MPET to give the box a sophisticated metallic shine. The boxes are printed with two coats of white, followed by a four-color process and a custom green PMS color. A soft-touch coating and spot gloss are applied to provide a premium finish.

Throughout the FDA approval process, Wynalda manufactured multiple small production runs, quickly producing new samples to meet the stringent requirements and tight deadlines. Wynalda’s Design and Prepress teams remained deeply involved, making numerous adjustments to ensure the packaging met all FDA criteria.

 

 

The Result

 

Wynalda’s responsiveness and speed-to-market enabled PharmaEssentia to maintain momentum throughout the FDA approval process, allowing their therapies to reach patients within the U.S. market as quickly as possible. The redesigned packaging was a success, enhancing both functionality and customer experience. PharmaEssentia was very pleased with the new packaging and very appreciative of Wynalda Packaging’s responsiveness to their demands.

“Wynalda has been an amazing partner. They have always taken our needs as a business very seriously, from the point when we were pre-commercial all the way until now. They do business honestly, they do what they say they are going to do, and they are amazingly reliable, predictable, and flexible.”

– Samuel Lin, Vice President of Business Operations & Strategy, PharmaEssentia USA

Jim Beam Bottle Hitchhiker Packaging

Jim Beam Bottle Hitchhiker Packaging

CASE STUDIES

 

Jim Beam Bottle Hitchhiker Packaging

Overview

 

ADM partnered with Wynalda Packaging to design a bottle hitchhiker for Jim Beam, one of the world’s most iconic bourbon whiskey brands. The hitchhiker hung from the neck of their 1.75-liter bourbon whiskey bottle and held a collapsible cooler as a promotional gift. This eye-catching packaging not only stood out on the crowded liquor aisle but also incentivized purchases by offering customers a free, practical gift with every bottle.

FEATURES

SPECIALTY COATINGS

STRUCTURAL DESIGN

DURABILITY

Structure & Materials

 

The hitchhiker was engineered as a straight tuck carton with a fifth-panel hang tab designed to securely attach the box to the bottle’s neck. Constructed from 24pt SBS, the packaging offered the strength and durability required to support the weight of the cooler, ensuring the hitchhiker remained intact throughout shipping and handling.

 

 

Printing & Coating

 

For additional promotional purposes, the hitchhiker was printed using four-color process. An overall gloss coating was applied for a sleek, polished look, while a spot dull varnish provided subtle contrast, accentuating specific details in the design. This combination of finishes elevated the overall presentation, reinforcing Jim Beam’s premium image.

Conclusion

 

This smart packaging solution allowed Jim Beam to include a substantial promotional item without significantly increasing the footprint of their packaging. The compact design takes up roughly the same space as the bottle alone—both in transit and on the shelf—yet adds considerable value to their product and enhances the consumer experience.

By combining strategic design, durable construction, and expert printing, we helped Jim Beam captivate consumers and drive sales in a competitive market.

Planning a limited-edition release or seasonal gift promo? Let’s design packaging that grabs attention and leaves a lasting impression. Get in touch with us today.

 

Hornitos Tequila Folding Carton Gift Packaging

Hornitos Tequila Folding Carton Gift Packaging

CASE STUDIES

Hornitos Tequila Folding Carton Gift Packaging

Overview

 

ADM partnered with Wynalda Packaging to develop a limited-edition margarita gift set for Hornitos Tequila, featuring a 750ml bottle of Plata tequila and a branded margarita glass.

As part of the Hornitos “Artist Edition” series, the packaging needed to showcase original artwork from a real artist while delivering durability, protection, and a premium shelf presence.

FEATURES

SPECIALTY COATINGS

FLUORESCENT INK

DURABILITY

Structure & Materials

 

To ensure strength and stability, we used 28pt SFI®-certified SBS, designed with a reinforced auto-lock bottom and double tuck closure. A gusset tuck with a tongue lock created clean, rolled edges and strong, secure corners.

Dual window cut-outs were added to highlight the tequila bottle and glass within. For internal protection, we engineered a custom insert made from 12pt SFI®-certified SBS laminated to E-flute, providing both product security and a premium appearance.

 

 

 

Printing & Finishing

 

The exterior of the box was printed with four-color process, plus a fluorescent yellow PMS color and Hornitos’ signature green PMS color for vibrant branding.

To elevate the tactile experience, we applied a combination of specialty coatings, including a dull varnish, spot gloss UV, and a reticulating coating, creating rich texture contrasts.

The interior insert was printed with a single PMS color and finished with a matte varnish for a clean, complementary look.

 

Conclusion

 

The final packaging successfully combined strength, style, and artistry, bringing the “Artist Edition” vision to life with a bold, gift-worthy presentation that celebrates both the product and the creative spirit behind it.

Planning a limited-edition release or seasonal gift promo? Let’s design packaging that grabs attention and leaves a lasting impression. 

Get in touch with us today.

 

 

Soft-Touch Boxes for Fab CBD

Soft-Touch Boxes for Fab CBD

CASE STUDIES

Soft-Touch Boxes For Fab CBD

The Challenge

 

Fab CBD, a premium hemp product brand, sought to enhance the sustainability of their packaging without compromising its luxurious look and feel. Their existing folding cartons were made from paperboard with a soft-touch laminate, which offered a rich texture and sophisticated aesthetic. However, the laminate contained plastic, reducing the cartons’ recyclability. Fab CBD needed a solution that would maintain the high-end finish that the soft-touch laminate provided while eliminating plastic to align with their sustainability goals.

FEATURES

SPECIALTY COATINGS

SUSTAINABILITY

DURABILITY

The Solution

 

Wynalda Packaging developed an innovative solution that met both the sustainability and aesthetic requirements. Instead of using soft-touch laminated paperboard, we transitioned to a standard 18pt SBS paperboard and used soft-touch coating to achieve the desired texture.

 

 

 

While a single layer of soft-touch coating provides a smooth, refined finish, it doesn’t quite match the rich, tactile feel of a laminate. To truly replicate that premium texture, we applied the soft-touch coating twice, using a second pass on press. The result was a remarkably luxurious tactile experience, virtually indistinguishable from a laminate, but without the plastic film.

To further enhance the sustainability of this project, we used an aqueous soft-touch coating rather than a UV coating. This water-based alternative reduces the emission of volatile organic compounds (VOCs) during drying and is more biodegradable and recyclable, making it a smarter, more eco-friendly choice.

We utilized this technique across Fab CBD’s product lines, ensuring consistency. Eachbox was printed with one of Fab CBD’s signature PMS colors, corresponding to the specific product line, and complemented with black accents for a polished and cohesive look.

 

 

 

The Results

 

The redesigned packaging successfully maintained Fab CBD’s premium aesthetic while reducing the environmental impact.

Want to explore innovative packaging solutions for your product? We are always happy to help. Speak with a packaging expert today!