Custom Tequila Packaging with Pulp Insert & Rotating Base | Full Development Case Study

Project Overview

• Client Type: Packaging Company
• Industry: Spirits (Tequila)
• Product Type: Rigid Gift Box with Pulp Insert & Rotating Base
• Project Focus: Design Support, Material Development & Assembly Execution
• Market: US

Client Challenge

This project required more than standard packaging production. The client needed a partner who could support both design realization and complex execution:

• Initial concept required structural refinement to match brand expectations
• Multiple components involved: pulp insert, rotating mechanism, ribbons, magnets, etc.
• Need to select the right materials and finishes across all elements
• Artwork included gradient colors, requiring precise color transition control
• Complex structure requiring manual assembly with consistent quality

 The key challenge was to integrate design, materials, and production into one cohesive solution.

Our Solution

1. Design Support & Structural Optimization

We worked closely with the client to refine the packaging concept:

• Assisted in box structure optimization for better usability and presentation
• Ensured the design was production-ready and structurally stable
• Balanced aesthetics, function, and manufacturability

 Result: Final structure aligned with both design intent and user experience

2. Full Material & Process Development

This project required careful coordination of multiple materials and components.

We provided:

• End-to-end material selection and sourcing, including:
  • Paper wrap, grey board, pulp insert
  • Rotating mechanism (shaft system)
  • Accessories (ribbons, magnets, etc.)
• Multiple finishing options and process recommendations
• Integration of all elements into a cohesive production solution

Result: Consistent quality across all components with a unified premium look

3. Advanced Color Control for Gradient Artwork

Gradient printing presents higher risks in color inconsistency.

We ensured:

• Smooth color transition and gradient consistency
• Strict color calibration during printing
• Controlled output across production batches

Result: Clean and refined gradient effect aligned with brand expectations

4. Handmade Assembly for Complex Structure

Due to the number of components, this product required full manual assembly.

We ensured:

• Skilled manual assembly for precision and consistency
• Strict process control for each component
• Stable output across all units

Result: High-quality finish with consistent assembly standards

Results & Impact

• Successfully delivered a complex, multi-component packaging solution
• Achieved strong alignment with brand positioning and design expectations
• Ensured stable quality across manual assembly production
• Strengthened client relationship through full-service support

Key Capabilities Demonstrated

Structural & Design Support

• Packaging structure optimization
• Design-to-production conversion
• Functional packaging development

 Material & Process Integration

• Multi-material sourcing and coordination
• Complex component integration
• Full development capability

 Color Management

• Gradient printing control
• Consistent color output
• High-precision visual execution

Production & Assembly

• Handmade packaging expertise
• Complex assembly management
• Stable production quality

Applications

• Tequila & spirits packaging
• Premium gift boxes with inserts
• Interactive or functional packaging
• Brand campaign packaging

Call to Action

Looking for a packaging partner who can handle complex structures and full development projects?

• Request a quotation
• Get material & structure consultation
• Start your custom packaging project