Jamie Matusow, Editor-in-Chief06.10.24
Value-added, secondary packaging, from folding cartons to set-up boxes, serves as a first impression of what a brand stands for, from luxury to sustainability—and beyond.
Over the last few years, especially in the U.S., the beauty industry has experienced an impressive double-digit dollar rise. While the Mass market has also grown, Prestige has been the overall standout. Last year, Prestige beauty’s growth in units sold, outperformed every other general merchandise and CPG industry tracked by omnichannel market analyst Circana.
Circana attributes the growth to a desire for purchasing “small luxuries,” items that consumers can buy as a treat for themselves—one that brings them joy.
This trend impacts both brick-and-mortar and online sales. As consumers become more focused on reading labels, secondary packaging has now leaped into the spotlight as the very first interaction consumers have with the product. Brands are capturing this opportunity to relay influential messages via various avenues including materials, sizes, colors, shapes, embossing, lasering, logos, graphic techniques, certifications, and more.
Today’s secondary packaging not only keeps products safe, but is thoughtfully designed to capture attention, make a lasting impression, and often, tell a compelling sustainability story—all at the same time. In effect, the right carton can influence and capture the consumer, and make the sale.
From special coatings to “wow” printing effects, to sustainable properties, here’s a look at what some of the cosmetic industry’s leading suppliers are offering their brand customers, based on new technologies and of-the-moment trends.
Many suppliers we spoke with refer to secondary packaging as a value-added component. Others point toward advanced technology for automation and production. Overall, sustainability seems to be the overarching concern among customers looking for cartons and boxes.
Goldman says their clients “are focused on how they can stand out from the competition in that split second the consumer views their product on the shelf.” He adds, “The current trend is a more natural look with matte finishes and spot gloss coatings for pop.”
In working with the Necessaire brand, one challenging project was the gift sets for Hair Essentials and Body Essentials. Goldman says Necessaire wanted a deep black, for which they used Neenah Industrial Black at the time. “The challenge,” he explains, “then became to print a bright clean white for the copy and image backgrounds, so that the photos would still pop as if they were printed on a white paperboard. And the coating wanted to dive into the porous material, so it was critical to get the right spot gloss level on the images.”
This Necessaire carton is indicative of the rise in brands using photos of the products directly on the carton—a true picture of what’s inside.
At NJ-based COII Packaging, which specializes in “value-added” folding cartons for the cosmetic packaging arena, Joe Cicci, President Emeritus, says, “Our quick response and abbreviated manufacturing time fits well with the promotional carton and commercial programs needed.”
Cicci says, “Our customers are eager to find value-added variations, creating shelf appeal, while remaining sustainable. We have been able to achieve this often through a number of our specialty in-line coatings, from faux micro-embossing to methane mitigation.” (See more on COII’s Biolithe seal later in this article.)
Brand enhancement through specialty printing is also a draw at Carlson Print Group. Earl Guinter, Business Development Manager, says they have a reputation for delivering innovative and premium packaging with their specialty print “which combines the latest materials, inks, coatings, and print embellishments (i.e, cold foil and cast & cure).”
Related: Decorative Effects to Elevate & Make An Impact
Guinter agrees with others we spoke to for this article—that brands within the same product category cohabit the same aisles, and the challenge is how to stand out with visible shelf-appeal. He says many of Carlson’s clients take advantage of their specialty print to drive attention to their packaging versus the competition. “Shiny and tactile print elements can increase visual presence on shelf,” he explains.
Rissmann, based in Nuremberg, Germany, designs, develops and manufactures premium packaging made of paper (unique bags & boxes) for luxury brands in cosmetics & fragrances, as well as in other markets.
Sophie Ivens, CEO, tells Beauty Packaging, that sustainability is vital to their customers, who prefer luxury boxes with a collapsible design that reduces storage and freight volume. She explains, “There is a shift away from magnetic closures toward more sustainable closure methods. Local production is growing in importance as customers value products that support local economies and reduce carbon footprints.”
Rissmann’s collapsible box from their “Green 360° collection,” is a “Box Bag” made from 100% paper and cardboard. Even the macrame carrying strap and the cardboard closure flap are made from FSC-certified paper. The “Box Bag” is a collapsible box with a reduced storage and freight volume with “a positive effect of lower C02 emissions,” according to Ivens.
Both, the box and the macrame carrying strap can be reused/repurposed in a variety of ways.
Ivens says the Box Bag is a solution “that seamlessly combines the functionality of both a gift box and shopping bag.” The unique folding technique was developed “without compromising high-quality, durability, and functionality.”
NJ-based DCC Packaging specializes in both offset and digital folding carton print production. Michael Rickett, Vice President of Packaging Sales, says they are known for their “quality, broad capabilities, and customer service with demanding luxury brands.” DCC works directly with its clients from structural design and development to printing and finishing, all in-house.
Rickett, like many of the packaging executives we spoke with, agrees that sustainability has been a significant trend in the folding carton industry, with a focus on recyclability, biodegradability, and using eco-friendly materials. Additionally, he says, advancements in printing technology have allowed for more intricate designs and customization options, catering to brand-specific needs and preferences.
“Digital printing, in particular, is gaining traction for its flexibility and cost-effectiveness in short print runs,” says Rickett. “Moreover, there’s a growing demand for packaging that enhances consumer engagement, such as interactive designs or QR codes for product information. Overall, the industry is evolving to meet both environmental concerns and consumer expectations for attractive, functional packaging solutions.”
Albert Paper Products is a NJ-based manufacturer of tertiary and secondary packaging for the cosmetic, beauty, and hair care industries. The company specializes in chip packers/inners, shippers, pads, liners, folding cartons, and partitions—all designed to brand and protect products. Mark Kenah, Vice President, says, “We are an extremely unique manufacturer as we can produce all of our components under one roof. Both paperboard and corrugated—a one-stop shop, so to speak.”
Voion provides a complete suite of packaging solutions across the spectrum, including corrugate manufacturing and converting, litho-laminate products, folding cartons, rigid box, paper-pulp structures (wet, semi-wet, and dry), foam inserts, booklets/book production and luxury packaging (including wood boxes, soft-shell cases, acrylic structures).
Rick Conant, VP Operations, Voion USA, tells Beauty Packaging, “With 45 offset and flexo presses, 75 rigid box auto assembly lines, 5 full-size corrugators, 40 pulp tray presses, and a complete host of post-press and automated systems, Voion covers all aspects of paper-based packaging worldwide.”
This is a turnkey operation, from packaging concept and ideation through to engineering, structural testing, 3D modeling, material testing (ISTA), pre-production sampling, mass production, logistics, and warehousing. Voion is based in South-China with other manufacturing locations in Vietnam, Thailand, Malaysia, Mexico, and Poland.
Cicci, of COII says while sustainability is a brand concern, “Customers are thirsty for eye-catching graphic techniques, which cosmetic packaging has always had. I’m glad to see this trend coming back.”
COII offers a dual solution by producing cartons with a Biolithe coating additive.
Cicci explains, “Biolithe is a patented natural low-cost additive to coating that can dramatically reduce the emission of methane gas during carton decomposition in landfills. Biolithe is FDA-approved, carbon-negative, non-toxic and safe.”
COII worked with The Dr. Idriss brand, which “is committed to sustainable packaging that really, positively impacts the environment.” Cicci says, “The Biolithe coating can be applied to all printed pieces of cellulose composition. These printed pieces can proudly display the Biolithe seal next to other sustainable seals such as FSC.”
Cicci says COII Packaging is the only carton manufacturer to-date that can print with the in-line Biolithe additive, “paving the way for real positive impact on our environment.”
At Albert, “Sustainability is no longer just a buzzword,” says Kenah. “It’s a priority for consumers and, consequently, for businesses.” He says the drive towards eco-friendly packaging solutions is stronger than ever, with a focus on materials that are recyclable, biodegradable, or compostable.
Beyond the material itself, minimalism in packaging design is also gaining traction, says Keough, reducing waste, and emphasizing simplicity and functionality. He says, “Albert Paper Products is at the forefront of this trend, offering sustainable packaging solutions that don’t compromise on quality or aesthetic appeal.”
Paper and board are also finding new uses as replacements for plastics.
VoionUSA’s Conant, says, “Perhaps the most obvious trend over the past 5 years is the push to eliminate most all plastics in retail and e-commerce packaging. Reducing the carbon footprint is critical to many business platforms and the path covers not only designing paper-based solutions, but also examining the complete sustainability picture.”
Voion recently produced packaging for GN Group, a Danish company, “which has been on the forefront of green-focused design for many years.” They tasked Voion to redesign their consumer electronic and hearing packaging that would “push the envelope on company-wide sustainability goals.” This involved removing all plastics, reducing the overall footprint of every box, and implementing materials that would be easily recycled worldwide. Other considerations included the capability to produce in different locations, such as ASEAN, EMEA, and NA.
Conant says Voion had to look closely at materials to ensure the product would not only be protected, but would arrive without any marks or abrasions. Ultimately, they incorporated some design tweaks that held all internal items snug, and ramped up the use of PLA (corn-based polymer) films and coatings that would help protect. “Then, says Conant, “making sure that we could continue the brand guidelines into the e-commerce platform was critical. The opening experience had to be similar but it also had to speak to the sustainability choices being made when this item arrived on a doorstep.”
When brands look for sustainable suppliers, guidelines can go far beyond the characteristics of the package itself.
Goldmann, at Arkay, says, “It varies, depending on the mission of the company/brand. However, everyone is interested to some degree and rightfully so. FSC certification is critical. While mylars and foils are still important for ‘bling,’ reduction of coverage and creative use of said materials is a focus.
Use of boards with PCR is rising as well. Most importantly, a supplier must have a holistic responsibility position in general to be appealing. What are they doing locally, how do they support their employees when it comes to physical and mental health, what creative alternatives are they developing for power, materials, and other resources?”
At Rissman, Ivens says, “Sustainability is fundamental and a basic requirement in the development of new packaging.” She finds that sustainability considerations in carton packaging include material selection, responsible sourcing, and the recyclability of the entire product so that it can be returned to the paper recycling bin at the end of its life.
Keith Traub, CEO/Founder of NJ-based Integrated Packaging Industries, Inc., says sustainable packaging “is one of the most significant areas of interest to many brands and clients”—and they are interested in the latest materials and solutions, such as 100% PCW (post-consumer waste) recycled and recyclable materials.
The 37-year-old company, which prides itself on customer service, created a sustainable, promotional carton, which Traub says “generated tremendous interest, and resulted in developing many new clients due to our expertise and capabilities in this area.”
Integrated Packaging incorporated a variety of colors and finishes, like spot UV, foil stamping, and embossing on 100% PCW recycled paperboard, to demonstrate “how packaging can look and feel amazing and still be sustainable.”
Carlson’s Guinter believes sustainability is important to most brands based on questions they are asked and how projects are developed. He says material selection is generally at the top of the list, such as clients asking for materials that have the look and performance of a typical SBS board, but with recycled content. He says they have a few material options to meet clients’ expectations.
When it comes to printing enhancements, Guinter says questions are asked about recyclability and reduced carbon footprint. He says, “Specialty print treatments meet the recyclability requirements and our use of LED UV ink curing technology is more energy-efficient.”
Recently, Carlson produced the carton for the Yves Saint Laurent (YSL) Travel Case Kit. The folding carton showcases four-color process printing, a brand blue color contrast alongside a rich black. The YSL logo is enhanced with silver cold foil and a sculpted emboss contrasted by the satin varnish. The back panel has a high-gloss coating over the four-color process graphics, enhancing the graphics.
Sustainable thinking played a role in producing the challenging project. Guinter explains that the YSL logo would have typically been done in hot foil stamping, but using inline cold foil achieved the same look while reducing the carbon footprint by eliminating the hot foil process—maintaining the rich black throughout the printing process, and keeping perfect registration between the sculpted emboss to the print. “We achieved the client’s expectations with a high-gloss appearance on the back panel to showcase the printed graphics,” says Guinter.
At DCC, Rickett says sustainability has become increasingly important for brands when considering packaging. “There’s a growing awareness among consumers about environmental issues, leading to a preference for eco-friendly products and packaging. Brands that prioritize sustainability can enhance their reputation and appeal to environmentally conscious consumers.”
Overall, Rickett says sustainability has become a crucial consideration for brands not only to meet consumer expectations, but contribute to brand differentiation and innovation, helping brands stand out in competitive markets.
DCC’s Whitney Houston Box was produced on 20PT C/1/S, printed 6/0: CMYK + 2 hits of a Pantone purple + O/A Satin AQ, silver-foil-stamped in 5 locations, and then die-cut and glued with a clear acetate window—a challenging project.
Rickett tells Beauty Packaging, that DCC conquered the challenges by “running the purples solid, nice and strong, while keeping all knock-out white copy open and readable.” Also, some of the silver foil was very small and thin so they needed to test multiple foils and releases to yield the best quality result. The die-cut scores also needed extra attention “to make sure with all the solid in color that we did not get any cracking.”
At The Paper Tube Company, David Molo, Founder, tells Beauty Packaging, that sustainability is the determining factor for most of their customers when it comes to making purchasing decisions.
He says customers are always looking for ways to stand out through unique construction, customization or artwork without sacrificing quality or sustainability.
The Paper Tube Company produced box packaging for the Day Rate Beauty Power Pins, as well as paper tubes for the mini pins. He says, “The uniquely shaped product required us to design a solution that kept the pin in place in a way that was easy to fulfill, was presentable, and was easily produced in large quantities.”
“As a leader in innovative packaging solutions,” Keough says, “Albert Paper Products is exploring ways to incorporate smart technologies that add value for our clients and their customers.”
Another factor in smart packaging is automation. Conant of VoionUSA, says, “Machine-based production has become more refined in the past few years—especially in rigid-box production—with robotics and laser-guided systems leading the way. He says each set-up needs to be configured independently, but this increases production output, reduces quality control issues, and lowers overall cost.”
Metal-Mania Radiates Luxury: Breaking Down the Benefits of Metal & Metalized Packaging
Over the last few years, especially in the U.S., the beauty industry has experienced an impressive double-digit dollar rise. While the Mass market has also grown, Prestige has been the overall standout. Last year, Prestige beauty’s growth in units sold, outperformed every other general merchandise and CPG industry tracked by omnichannel market analyst Circana.
Circana attributes the growth to a desire for purchasing “small luxuries,” items that consumers can buy as a treat for themselves—one that brings them joy.
This trend impacts both brick-and-mortar and online sales. As consumers become more focused on reading labels, secondary packaging has now leaped into the spotlight as the very first interaction consumers have with the product. Brands are capturing this opportunity to relay influential messages via various avenues including materials, sizes, colors, shapes, embossing, lasering, logos, graphic techniques, certifications, and more.
Today’s secondary packaging not only keeps products safe, but is thoughtfully designed to capture attention, make a lasting impression, and often, tell a compelling sustainability story—all at the same time. In effect, the right carton can influence and capture the consumer, and make the sale.
From special coatings to “wow” printing effects, to sustainable properties, here’s a look at what some of the cosmetic industry’s leading suppliers are offering their brand customers, based on new technologies and of-the-moment trends.
The Latest Trends in Cartons
Our research points to carton and set-up box suppliers that are continuously developing more sustainable packaging to meet both brand and consumer demand—and designed to spark interest and showcase the product inside.Many suppliers we spoke with refer to secondary packaging as a value-added component. Others point toward advanced technology for automation and production. Overall, sustainability seems to be the overarching concern among customers looking for cartons and boxes.
Value-Added Features
Arkay Packaging, with headquarters in NY and Roanoke, VA, holds Platinum status from Ecovadis, and specializes in value-added printing and finishing for secondary packaging. Gregg Goldman, Director of Sales, tells Beauty Packaging “We excel when it comes to attention to detail, flexibility, agility and project management.”Goldman says their clients “are focused on how they can stand out from the competition in that split second the consumer views their product on the shelf.” He adds, “The current trend is a more natural look with matte finishes and spot gloss coatings for pop.”
In working with the Necessaire brand, one challenging project was the gift sets for Hair Essentials and Body Essentials. Goldman says Necessaire wanted a deep black, for which they used Neenah Industrial Black at the time. “The challenge,” he explains, “then became to print a bright clean white for the copy and image backgrounds, so that the photos would still pop as if they were printed on a white paperboard. And the coating wanted to dive into the porous material, so it was critical to get the right spot gloss level on the images.”
This Necessaire carton is indicative of the rise in brands using photos of the products directly on the carton—a true picture of what’s inside.
At NJ-based COII Packaging, which specializes in “value-added” folding cartons for the cosmetic packaging arena, Joe Cicci, President Emeritus, says, “Our quick response and abbreviated manufacturing time fits well with the promotional carton and commercial programs needed.”
Cicci says, “Our customers are eager to find value-added variations, creating shelf appeal, while remaining sustainable. We have been able to achieve this often through a number of our specialty in-line coatings, from faux micro-embossing to methane mitigation.” (See more on COII’s Biolithe seal later in this article.)
Brand enhancement through specialty printing is also a draw at Carlson Print Group. Earl Guinter, Business Development Manager, says they have a reputation for delivering innovative and premium packaging with their specialty print “which combines the latest materials, inks, coatings, and print embellishments (i.e, cold foil and cast & cure).”
Related: Decorative Effects to Elevate & Make An Impact
Guinter agrees with others we spoke to for this article—that brands within the same product category cohabit the same aisles, and the challenge is how to stand out with visible shelf-appeal. He says many of Carlson’s clients take advantage of their specialty print to drive attention to their packaging versus the competition. “Shiny and tactile print elements can increase visual presence on shelf,” he explains.
Rissmann, based in Nuremberg, Germany, designs, develops and manufactures premium packaging made of paper (unique bags & boxes) for luxury brands in cosmetics & fragrances, as well as in other markets.
Sophie Ivens, CEO, tells Beauty Packaging, that sustainability is vital to their customers, who prefer luxury boxes with a collapsible design that reduces storage and freight volume. She explains, “There is a shift away from magnetic closures toward more sustainable closure methods. Local production is growing in importance as customers value products that support local economies and reduce carbon footprints.”
Rissmann’s collapsible box from their “Green 360° collection,” is a “Box Bag” made from 100% paper and cardboard. Even the macrame carrying strap and the cardboard closure flap are made from FSC-certified paper. The “Box Bag” is a collapsible box with a reduced storage and freight volume with “a positive effect of lower C02 emissions,” according to Ivens.
Both, the box and the macrame carrying strap can be reused/repurposed in a variety of ways.
Ivens says the Box Bag is a solution “that seamlessly combines the functionality of both a gift box and shopping bag.” The unique folding technique was developed “without compromising high-quality, durability, and functionality.”
NJ-based DCC Packaging specializes in both offset and digital folding carton print production. Michael Rickett, Vice President of Packaging Sales, says they are known for their “quality, broad capabilities, and customer service with demanding luxury brands.” DCC works directly with its clients from structural design and development to printing and finishing, all in-house.
Rickett, like many of the packaging executives we spoke with, agrees that sustainability has been a significant trend in the folding carton industry, with a focus on recyclability, biodegradability, and using eco-friendly materials. Additionally, he says, advancements in printing technology have allowed for more intricate designs and customization options, catering to brand-specific needs and preferences.
“Digital printing, in particular, is gaining traction for its flexibility and cost-effectiveness in short print runs,” says Rickett. “Moreover, there’s a growing demand for packaging that enhances consumer engagement, such as interactive designs or QR codes for product information. Overall, the industry is evolving to meet both environmental concerns and consumer expectations for attractive, functional packaging solutions.”
One-Stop Shopping for Secondary Packaging
Convenience can be an important factor in projects going smoothly, from design to delivery, shipping, communication, and more.Albert Paper Products is a NJ-based manufacturer of tertiary and secondary packaging for the cosmetic, beauty, and hair care industries. The company specializes in chip packers/inners, shippers, pads, liners, folding cartons, and partitions—all designed to brand and protect products. Mark Kenah, Vice President, says, “We are an extremely unique manufacturer as we can produce all of our components under one roof. Both paperboard and corrugated—a one-stop shop, so to speak.”
Voion provides a complete suite of packaging solutions across the spectrum, including corrugate manufacturing and converting, litho-laminate products, folding cartons, rigid box, paper-pulp structures (wet, semi-wet, and dry), foam inserts, booklets/book production and luxury packaging (including wood boxes, soft-shell cases, acrylic structures).
Rick Conant, VP Operations, Voion USA, tells Beauty Packaging, “With 45 offset and flexo presses, 75 rigid box auto assembly lines, 5 full-size corrugators, 40 pulp tray presses, and a complete host of post-press and automated systems, Voion covers all aspects of paper-based packaging worldwide.”
This is a turnkey operation, from packaging concept and ideation through to engineering, structural testing, 3D modeling, material testing (ISTA), pre-production sampling, mass production, logistics, and warehousing. Voion is based in South-China with other manufacturing locations in Vietnam, Thailand, Malaysia, Mexico, and Poland.
Sustainability Rules for Cartons
All of the suppliers we spoke with for this story highlighted some key industry concerns around sustainability—but to different degrees.Cicci, of COII says while sustainability is a brand concern, “Customers are thirsty for eye-catching graphic techniques, which cosmetic packaging has always had. I’m glad to see this trend coming back.”
COII offers a dual solution by producing cartons with a Biolithe coating additive.
Cicci explains, “Biolithe is a patented natural low-cost additive to coating that can dramatically reduce the emission of methane gas during carton decomposition in landfills. Biolithe is FDA-approved, carbon-negative, non-toxic and safe.”
COII worked with The Dr. Idriss brand, which “is committed to sustainable packaging that really, positively impacts the environment.” Cicci says, “The Biolithe coating can be applied to all printed pieces of cellulose composition. These printed pieces can proudly display the Biolithe seal next to other sustainable seals such as FSC.”
Cicci says COII Packaging is the only carton manufacturer to-date that can print with the in-line Biolithe additive, “paving the way for real positive impact on our environment.”
At Albert, “Sustainability is no longer just a buzzword,” says Kenah. “It’s a priority for consumers and, consequently, for businesses.” He says the drive towards eco-friendly packaging solutions is stronger than ever, with a focus on materials that are recyclable, biodegradable, or compostable.
Beyond the material itself, minimalism in packaging design is also gaining traction, says Keough, reducing waste, and emphasizing simplicity and functionality. He says, “Albert Paper Products is at the forefront of this trend, offering sustainable packaging solutions that don’t compromise on quality or aesthetic appeal.”
Paper and board are also finding new uses as replacements for plastics.
VoionUSA’s Conant, says, “Perhaps the most obvious trend over the past 5 years is the push to eliminate most all plastics in retail and e-commerce packaging. Reducing the carbon footprint is critical to many business platforms and the path covers not only designing paper-based solutions, but also examining the complete sustainability picture.”
Voion recently produced packaging for GN Group, a Danish company, “which has been on the forefront of green-focused design for many years.” They tasked Voion to redesign their consumer electronic and hearing packaging that would “push the envelope on company-wide sustainability goals.” This involved removing all plastics, reducing the overall footprint of every box, and implementing materials that would be easily recycled worldwide. Other considerations included the capability to produce in different locations, such as ASEAN, EMEA, and NA.
Conant says Voion had to look closely at materials to ensure the product would not only be protected, but would arrive without any marks or abrasions. Ultimately, they incorporated some design tweaks that held all internal items snug, and ramped up the use of PLA (corn-based polymer) films and coatings that would help protect. “Then, says Conant, “making sure that we could continue the brand guidelines into the e-commerce platform was critical. The opening experience had to be similar but it also had to speak to the sustainability choices being made when this item arrived on a doorstep.”
When brands look for sustainable suppliers, guidelines can go far beyond the characteristics of the package itself.
Goldmann, at Arkay, says, “It varies, depending on the mission of the company/brand. However, everyone is interested to some degree and rightfully so. FSC certification is critical. While mylars and foils are still important for ‘bling,’ reduction of coverage and creative use of said materials is a focus.
Use of boards with PCR is rising as well. Most importantly, a supplier must have a holistic responsibility position in general to be appealing. What are they doing locally, how do they support their employees when it comes to physical and mental health, what creative alternatives are they developing for power, materials, and other resources?”
At Rissman, Ivens says, “Sustainability is fundamental and a basic requirement in the development of new packaging.” She finds that sustainability considerations in carton packaging include material selection, responsible sourcing, and the recyclability of the entire product so that it can be returned to the paper recycling bin at the end of its life.
Keith Traub, CEO/Founder of NJ-based Integrated Packaging Industries, Inc., says sustainable packaging “is one of the most significant areas of interest to many brands and clients”—and they are interested in the latest materials and solutions, such as 100% PCW (post-consumer waste) recycled and recyclable materials.
The 37-year-old company, which prides itself on customer service, created a sustainable, promotional carton, which Traub says “generated tremendous interest, and resulted in developing many new clients due to our expertise and capabilities in this area.”
Integrated Packaging incorporated a variety of colors and finishes, like spot UV, foil stamping, and embossing on 100% PCW recycled paperboard, to demonstrate “how packaging can look and feel amazing and still be sustainable.”
Carlson’s Guinter believes sustainability is important to most brands based on questions they are asked and how projects are developed. He says material selection is generally at the top of the list, such as clients asking for materials that have the look and performance of a typical SBS board, but with recycled content. He says they have a few material options to meet clients’ expectations.
When it comes to printing enhancements, Guinter says questions are asked about recyclability and reduced carbon footprint. He says, “Specialty print treatments meet the recyclability requirements and our use of LED UV ink curing technology is more energy-efficient.”
Recently, Carlson produced the carton for the Yves Saint Laurent (YSL) Travel Case Kit. The folding carton showcases four-color process printing, a brand blue color contrast alongside a rich black. The YSL logo is enhanced with silver cold foil and a sculpted emboss contrasted by the satin varnish. The back panel has a high-gloss coating over the four-color process graphics, enhancing the graphics.
Sustainable thinking played a role in producing the challenging project. Guinter explains that the YSL logo would have typically been done in hot foil stamping, but using inline cold foil achieved the same look while reducing the carbon footprint by eliminating the hot foil process—maintaining the rich black throughout the printing process, and keeping perfect registration between the sculpted emboss to the print. “We achieved the client’s expectations with a high-gloss appearance on the back panel to showcase the printed graphics,” says Guinter.
At DCC, Rickett says sustainability has become increasingly important for brands when considering packaging. “There’s a growing awareness among consumers about environmental issues, leading to a preference for eco-friendly products and packaging. Brands that prioritize sustainability can enhance their reputation and appeal to environmentally conscious consumers.”
Overall, Rickett says sustainability has become a crucial consideration for brands not only to meet consumer expectations, but contribute to brand differentiation and innovation, helping brands stand out in competitive markets.
DCC’s Whitney Houston Box was produced on 20PT C/1/S, printed 6/0: CMYK + 2 hits of a Pantone purple + O/A Satin AQ, silver-foil-stamped in 5 locations, and then die-cut and glued with a clear acetate window—a challenging project.
Rickett tells Beauty Packaging, that DCC conquered the challenges by “running the purples solid, nice and strong, while keeping all knock-out white copy open and readable.” Also, some of the silver foil was very small and thin so they needed to test multiple foils and releases to yield the best quality result. The die-cut scores also needed extra attention “to make sure with all the solid in color that we did not get any cracking.”
At The Paper Tube Company, David Molo, Founder, tells Beauty Packaging, that sustainability is the determining factor for most of their customers when it comes to making purchasing decisions.
He says customers are always looking for ways to stand out through unique construction, customization or artwork without sacrificing quality or sustainability.
The Paper Tube Company produced box packaging for the Day Rate Beauty Power Pins, as well as paper tubes for the mini pins. He says, “The uniquely shaped product required us to design a solution that kept the pin in place in a way that was easy to fulfill, was presentable, and was easily produced in large quantities.”
Smart Packaging
At Albert, the integration of technology into packaging, known as smart packaging, is “revolutionizing” how brands interact with their consumers. This trend encompasses everything from QR codes that lead to immersive digital experiences to packaging with built-in freshness sensors. Keough says these innovations not only enhance the consumer experience, but also provide valuable data to businesses about customer interactions and product lifecycle.“As a leader in innovative packaging solutions,” Keough says, “Albert Paper Products is exploring ways to incorporate smart technologies that add value for our clients and their customers.”
Another factor in smart packaging is automation. Conant of VoionUSA, says, “Machine-based production has become more refined in the past few years—especially in rigid-box production—with robotics and laser-guided systems leading the way. He says each set-up needs to be configured independently, but this increases production output, reduces quality control issues, and lowers overall cost.”
Forward Focus
For brands that are focused on standing out from the competition and instantly relaying a story, the right carton, set-up box, materials or manufacturing process can make all the difference.Read Next
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