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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Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

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Dr. Squatch Discovery Pack Cologne Packaging

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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.

Case Studies

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Sustainable, Anti-Theft Packaging Redesign for PopSockets

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Secondary Packaging for Maker’s Mark Wood Finishing City Series

Dr. Squatch Discovery Pack Cologne Packaging

Dr. Squatch Discovery Pack Cologne Packaging

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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.

Case Studies

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

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Sustainable, Anti-Theft Packaging Redesign for PopSockets

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Dr. Squatch Discovery Pack Cologne Packaging

Dr. Squatch Discovery Pack Cologne Packaging

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Limited Edition Packaging for Goose Island Beer Co.

Limited Edition Packaging for Goose Island Beer Co.

Dec 11, 2025

CASE STUDIES

 

Limited Edition Packaging for Goose Island Beer Co.

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Project Overview

 

ADM partnered with Wynalda Packaging to create luxury, stand-out packaging for the limited edition release of Goose Island Beer Co.’s King Henry II Barrel-Aged Barleywine. The goal was to design a structure and finish that reflected the rarity and craftsmanship of the beer, delivering an elevated and memorable unboxing experience.

To achieve this, Wynalda developed a custom drawer-style rigid box paired with a paperboard slipcase and a layered insert, combining structural creativity with refined detailing for a truly luxurious presentation.

FEATURES

SPECIALTY COATINGS

EMBOSSING

COLD FOIL

OUR CAPABILITIES

Rigid Box

 

A rigid box serves as the primary structural element for this package, constructed from 60pt chipboard with both an outer wrap and inner liner. 

  • Inner Liner: printed with 2 PMS colors and coated with an overall soft-touch coating.
  • Outer Wrap: printed with 4-color process plus 2 PMS colors and coated with an overall soft-touch coating.
  • Enhancements: Cold foil accents add depth and a rich metallic sheen, underscoring the exclusivity of the King Henry II release.

Paperboard Insert

 

Inside the rigid box rests a three-layer 18pt SBS insert, each layer precisely cutout revealing the layer beneath, creating a sense of depth and dimension. Printed with 3 PMS colors, cold foil, and an overall soft-touch coating, the insert maintains the cohesive aesthetic of the full package. A lift tab adds functionality and ensures a seamless unboxing experience. Achieving perfect registration across all layers required meticulous gluing and alignment, demonstrating Wynalda Packaging’s attention to detail and manufacturing precision.

Paperboard Slipcase

 

The outer slipcase was designed to make an immediate impression. Crafted from 18pt SBS, it features a rolled edge bottom and tuck top with a tongue lock for secure closure. Cut-outs on the front and back of the slipcase add another layer to the dimensional reveal. 

 

 

 

In tandem with the rest of the package, the slipcase features gold cold foil, 2 custom PMS colors, and an overall soft-touch coating. For the final touch, blind embossing adds a tactile, elegant finish that communicates luxury from the first glance.

The Result

 

The final package stands as a testament to collaboration, precision, and design excellence. Through the combination of thoughtful structure, rich materials, and luxurious finishes, Wynalda Packaging helped ADM and Goose Island transform a limited-edition beer into an unforgettable brand experience. 

 

Case Studies

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

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Modular Rigid Box Packaging for TruDiagnostic

Modular Rigid Box Packaging for TruDiagnostic

Sep 24, 2025

CASE STUDIES

 

Modular Rigid Box Packaging for TruDiagnostic

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The Challenge

 

TruDiagnostic, a leading health data company specializing in advanced biological age testing, needed a unified packaging solution for three distinct product versions: TruHealth, TruAge, and the TruDiagnostic Bundle. Their primary goals were to streamline their packaging across all versions while maintaining product distinction—all in a cost-efficient manner.

 

FEATURES

 

 

SPECIALTY COATINGS

 

 

COST EFFICIENCY

 

 

DURABILITY

OUR CAPABILITIES

Our Solution

 

Wynalda Packaging engineered a modular solution that streamlined production by using a single rigid box across all three product versions. Customizable paperboard sleeves and inserts provided the flexibility to differentiate each product, balancing cost efficiency with product distinction.

 

 

The solution included:

 

  • A rigid telescoping base-and-lid box crafted from .058 white-lined chipboard, wrapped in 80# text stock.
  • A custom O-sleeve made from 18pt SBS C1S, featuring vibrant 4-color printing, an overall dull varnish, and spot gloss UV to highlight brand elements.
  • A paperboard insert, also made from 18pt SBS C1S, printed in full color and finished with an aqueous gloss coating for a clean, professional look.

The Results

 

By standardizing the rigid box and allowing for interchangeable sleeves and inserts, this modular approach provided the flexibility to distinguish each product while capitalizing on economies of scale. It also streamlined inventory management and delivered a cohesive, elevated brand experience across all variants.

Ready to unlock packaging efficiencies that save time and costs? Connect with us today!

 

Case Studies

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Rigid Box with Paperboard Insert for EDJY Toenail Cutters

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Sustainable, Anti-Theft Packaging Redesign for PopSockets

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Secondary Packaging for Maker’s Mark Wood Finishing City Series

Dr. Squatch Discovery Pack Cologne Packaging

Dr. Squatch Discovery Pack Cologne Packaging

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