ANTALIS Packaging has demonstrated the capabilities of its recently launched premium packaging service by developing a direct mail campaign to safely deliver a fragile chocolate egg while creating a memorable customer experience.
The project was designed to showcase how the firm can support customers through every stage of the premium packaging journey from concept and material selection through to structural design, production and fulfilment.
Delivering a chocolate egg through the postal network presented a challenge, as the packaging needed to provide protection while creating an engaging unboxing experience.
The finished mailer comprised three bespoke packaging components, each designed to perform a specific role. The chocolate egg was housed within a custom-designed moulded pulp egg box, chosen for its shock absorption properties. The pulp insert incorporated an integrated locking closure to secure the product during transit, while remaining fully recyclable and biodegradable. The moulded pulp insert was then presented inside a presentation carton manufactured from Antalis’ board Keaykolour Lipstick 300gsm. The carton featured curved profiles, layered structural folds, and a glue-free locking design, designed to show how cutting and folding techniques can eliminate adhesives whilst producing a premium finish.
Printed digitally on an HP Indigo 1200 digital press and precision cut using a Kongsberg X24 digital cutter, Antalis added that the carton also illustrated how ‘striking’ visual impact can be achieved using a simple single colour print process. White graphics printed onto the coloured board created a ‘tactile’ finish while maximising the branding space.
The presentation carton was enclosed within an e-commerce mailing box manufactured from lightweight E-flute board. The outer carton eliminated the need for void fill while incorporating a peel-and-seal closure and tear-strip.
Sustainability was central to the project. The moulded pulp insert is recyclable and biodegradable, the Keaykolour board is FSC-certified with an Antalis Green Star rating of 3, and the outer E-flute carton is said to be manufactured from sustainably sourced fibre and fully recyclable.
Emma Brown, premium packaging lead at Antalis UK, said, “Businesses are looking for much more than a packaging supplier. They want a partner who can help them balance creativity, sustainability, operational efficiency and customer experience. Antalis’ premium packaging service brings all those disciplines together under one roof, enabling customers to move from an initial idea through design, prototyping, production and fulfilment with a single trusted partner.”
Verity Mottram, creative design lead, added, “Using a chocolate egg gave us the perfect opportunity to demonstrate how structural packaging design can solve a genuine logistical challenge whilst still creating a memorable brand experience. Every design decision was carefully considered, from the protective moulded pulp insert through to the presentation carton and e-commerce box, ensuring the packaging delivered on protection, sustainability, ease of fulfilment and visual impact.”
