Projects · Packaging Development
Every package tells a story. Every project solves a challenge.
Discover some of the projects developed — not just the final result, but all the reasoning that led each solution to production.
Portfolio
Developed projects
Each case presents the problem, the decisions made and the result obtained.
Organic product line packaging
Structural redesign to eliminate accidental opening during transport and shelf display.
View case studySkincare gift set
Case with internal paper tray for three products of different sizes, without plastic.
View case studySecondary packaging with serialization
Carton with tamper-evident opening and reserved area for serialization per regulation.
View case studyShipping packaging with unboxing experience
Shipping box with ribbon opening and internal support mounted on the same die as the outer box.
View case studyCase Studies
The reasoning behind each solution
The final package is just the last step. The value lies in the process that got there.
Contexto
A package that could not withstand real use
The client produced a line of dry organic products with carton packaging. The problem came before the formal order: packages were being returned by distributors for opening during transport. The product arrived at the point of sale already compromised.
Desafio
Fragile structure, artwork already approved
The brief had a critical restriction: the graphic artwork had already been approved by the client and could not be significantly changed. The solution needed to be structural — and invisible to the end consumer. Additionally, the existing die supplier had to be maintained to avoid additional tooling costs.
Solução
Improved locking, same die
After analyzing the original dieline, we identified that the problem lay in the insufficient depth of the lid snap and the length of the locking ear. We redesigned only those geometries, maintaining the external perimeter of the original die. This allowed reuse of existing tooling with minimal adjustment. The new dieline was prototyped in three iterations before returning to the supplier for production.
Resultado
Zero occurrences, controlled cost
In the first three months after the change, no accidental opening occurred. The tooling adjustment cost was less than 15% of what a new dieline from scratch would have cost. The artwork kept its original approval, with bleeds adjusted for the new score with no visual impact.
Contexto
Three-product kit, a single tooling cost
The skincare brand wanted to launch a gift set with three line products — a 30ml serum, a 50ml moisturizer and a 15g mask — all in distinct primary packaging. The packaging needed to communicate premium without using EVA, plastic or internal foam.
Desafio
Three different formats, a single paper solution
The greatest difficulty was ensuring fixed positioning of all three items without plastic material, in a case that needed to be assembled manually at small scale. Each product had different dimensions and weights, making tray tolerance calculation critical — any excessive play and the products would shift during transport.
Solução
Tray cut on the same die as the case
We developed an internal tray in duplex board with three individual slots, each calculated with 1.5mm tolerance for a firm fit without excessive pressure. The geometry was designed so the tray could be cut with the same tooling as the outer case — with the addition of internal cuts only. This eliminated the cost of a second die. Four physical prototypes were produced before final approval.
Resultado
100% paper, passed drop test
The final packaging is 100% paper, recyclable and assembled manually in under 40 seconds. Tooling cost came in 40% below the initial budget by eliminating the second die. The 80cm drop test on all four faces recorded no internal movement or damage to primary packaging.
Competencies
What each project applies
Structural Development
Dieline design with specialized tools, considering material, cutting equipment and assembly behavior.
Packaging Engineering
Strength analysis, tolerances, grain direction and material behavior under load and temperature.
Physical Prototyping
Production of real prototypes for assembly, fit and resistance validation before any tooling investment.
Production Optimization
Intelligent dieline nesting, reuse of existing die, reduction of unnecessary cuts — lower cost without compromising structure.
Integrated Prepress
Artwork developed on the actual dieline — bleeds, scores and print direction already considered before final approval.
Technical Specification
Complete documentation for the supplier: material, thickness, score type, assembly instructions. No ambiguities.
Each project represents a combination of functionality, production feasibility and end-user experience. Our goal is not just to create beautiful packages, but to develop solutions that work throughout the entire production chain.
— Filosofia de desenvolvimento · inPressão Packaging