Packaging Case Study
Custom Restaurant Gift Card Box with a Tiered Paperboard Insert
A German event company needed a premium presentation box for a limited-edition restaurant gift card collection. The packaging had to display 14 heavy cards in clear stepped rows, protect matching invitations during transport and be ready within a demanding 20-day production window.
The Brief
A premium box for a complex multi-card experience
Each set contained one presentation box, 14 restaurant cards and 13 or more matching invitations. The first card introduced the participating restaurants, while the remaining cards presented individual chefs, signature dishes and restaurant stories. The client wanted every card to remain visible in an elegant stepped arrangement instead of lying flat in a stack.
The launch followed a limited sales schedule. Quantities and artwork were still changing while restaurant partnerships were being finalized, so the project required both premium quality and unusually flexible production planning. We formed a dedicated project team to coordinate artwork, quantities, sampling and manufacturing.
Challenge One
Recovering rich food colors without losing the premium finish
The original concept used textured uncoated specialty paper to create a natural tactile appearance. However, the artwork relied on large areas of saturated color. The uncoated surface absorbed too much ink, leaving the food photography and graphics dull.
After testing, we recommended coated art paper with CMYK plus two spot colors. This produced stronger contrast, more appetizing food imagery and a cleaner luxury finish while maintaining accurate brand colors across the box and cards.
Challenge Two
Developing a strong, economical tiered insert
The insert was the most demanding part of the project. Fourteen cards with invitations created significant weight, yet the display still needed to look refined and use environmentally responsible materials.
Several concepts were rejected: molded pulp required tooling that was not economical at this volume; acrylic and foam did not match the desired premium character; and many paperboard structures either collapsed in transit, required too much hand assembly or were visually bulky.
After extensive prototyping, we developed a black-core paperboard insert formed into a ladder structure and bonded to the side walls. A complementary sloped support in the lid helped stabilize the cards. The final design balanced appearance, cost, manufacturability and shipping protection, and the client continued using it for repeat orders.
Production Control
Preventing invitation mix-ups and ensuring reliable card removal
One restaurant per assembly line
The project included many German-language card and invitation versions that had to match exactly. To reduce sorting errors, each production line handled only one restaurant version at a time. When a restaurant required multiple invitation versions, one version was completed before the next began.
Controlled invitation slots
The invitation pocket was formed by debossing wrapped paperboard. We tested the maximum practical invitation thickness and standardized it at up to 300 gsm coated paper. Debossing depth, adhesive quantity and glue spread were controlled together so invitations could slide out smoothly without becoming loose.
Quality and Shipping
Testing the complete set, not only the empty box
- Checked lid and base colors under consistent lighting to prevent visible color differences.
- Verified every card and invitation version against the matching restaurant artwork.
- Inspected surfaces for dirt, scratches and finishing defects.
- Loaded the complete set, repeatedly inverted the box and checked whether any cards escaped the insert or leaned out of position.
- Packed eight boxes per reinforced K=K export carton and secured cartons on plastic pallets with layered moisture protection and rigid outer panels.
Client Result
“Shenzhen Kexin impressed with their rapid delivery and timeliness. The quality of the packaging materials was top-notch, durable, and visually appealing. Their customer service was exceptional, with quick responses and a tailored approach. In summary, Shenzhen Kexin offers an excellent overall package of service, quality, and design. Overall rating: highly recommended.”
The client placed repeat orders for the project over several consecutive years.
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