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

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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!

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

Custom Molded Pulp Trays For Chocolate Bunnies

Custom Molded Pulp Trays For Chocolate Bunnies

Jul 17, 2024

CASE STUDIES

 

Custom Molded Pulp Trays For Chocolate Bunnies

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The Challenge

 

A large chocolate company had been facing a significant challenge with their direct-to-consumer chocolate bunnies一their ecommerce products were frequently arriving cracked. Their initial packaging solution involved wrapping the bunnies in bubble wrap, which proved insufficient in protecting the delicate products during transit. This not only led to customer dissatisfaction but also increased the cost due to replacements and returns. 

Recognizing the need for a more effective and sustainable solution, they sought a packaging method that could provide protection for their product while aligning with their commitment to environmental sustainability.

FEATURES

BIODEGRADABLE

RECYCLED MATERIAL

DURABILITY

OUR CAPABILITIES

The Solution

Wynalda Packaging stepped in to solve this problem by designing a custom molded pulp tray for the chocolate bunnies. This innovative packaging solution involved creating a tray that snugly fit around the bunny, ensuring that no part of the product was more than 3mm away from the surface of the tray. This close fit provided optimal protection against impacts and vibrations during shipping.

Wynalda Packaging provided samples for drop testing, allowing them to work together to refine the packaging and create a product with maximized protective capabilities. The molded pulp, made from up to 100% recycled materials and fully biodegradable, not only offered exceptional protection but also aligned perfectly with the company’s sustainability goals.

 

 

The Results

The implementation of the custom molded pulp tray drastically reduced the incidence of cracking during transit, significantly improving customer satisfaction and reducing the costs associated with product damage and returns.

This innovative packaging solution positioned this company as a leader in the industry, being one of the first to adopt molded pulp for shipping delicate products directly to consumers.

This solution was so effective that they are now expanding the use of this packaging technique to some of their other products, further enhancing their reputation for both quality and sustainability.

By adopting this advanced and eco-friendly packaging solution, they provided a compelling example of how companies can innovate to meet both environmental and operational goals. 

Talk with a packaging expert to learn how you can use innovative packaging to protect your products and the planet.

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