The client’s objective was to achieve a premium carton for its aspirational The One spirits line, showcasing the brand with co-ordinated packs in different colours across the range, featuring a cohesive design and tactile appeal. The goal was to articulate the quality of the product through the choice of a thick, rigid folding box board and highly decorative finishes.

It was also important to meet the client’s aspiration for a fully recyclable and biodegradable carton.

Invercote Duo 790gsm board was chosen to meet the client’s expectation of a robust carton with a high-quality look and feel and recyclability.

The design involved delivery of an embossed quatrefoil image on the front of the carton, using a combination of UV inks and varnishes and incorporating different levels of emboss and foiling.

The Herbert Walkers team used our in-house CNC equipment to create bespoke embossing dies capable of working with the stiff board chosen for the project. Production of the cartons involved multiple passes through each process to deliver multilevel embossing with tight registration of foils and spot UV varnishes, ensuring a premium result that delivers both visual and tactile impact.

The cartons feature a glued crash lock and base to allow shipment to the client’s distillery for product packing, and a double-faced glue seam has been incorporated to avoid raw edges and enhance the premium look. We carried out enhanced transit testing to ensure the cartons can endure the rigours of supply chain movements.