Lindt Chocolate's latest PR hit – Packing 27 chocolate bars in a super-sized collapsible rigid box
When it comes to Lindt Chocolate, everything is premium. Each chocolate recipe tastes so divine that you’re torn between whether to devour it the very second or, to portion it for delayed pleasure!
Lindt’s focus on continuous innovation and growth consequently means that the company is always looking for new challenges.
So, it was no surprise when Lindt’s packaging design team once again came to The Mailer Box packaging with the challenge of developing a supersized box for 27 bars of their classic milk chocolates!
We at The Mailer Box love a good packaging challenge – that is how the company grows! This is what the final result looked like!
There was no debate about the type of box needed for this project – only a rigid box could deliver the desired high-end packaging look.
Rigid boxes are a type of packaging that is made from, well, more rigid materials such as grey-board or paper board, which is then layered with printed (designed) paper. As opposed to corrugated packaging which gets its strength from types of fluting and wall construction, rigid boxes get their strength from the rigidity of their base material.
These boxes are typically the choice for high-end or premium products mainly because they maintain their structure and shape nicely.
However, rigid boxes are known to be space-consuming both for shipping and storage.
For Lindt Chocolate’s special demand, this rigidity was likely to become a significant logistical difficulty. Since the box itself was giant, minimizing storage and ensuring efficient logistics also became critical success factors for this premium packaging project.
To effectively solve this puzzle, The Mailer Box recommended that Lindt opts for a collapsible rigid box instead. We explained that a collapsible or foldable rigid box would maintain the look and feel of luxury packaging and could be shipped and stored flattened thus meeting all of the key requirements for our remarkable customer.
What are collapsible Rigid Boxes?
Instead of a lift-off lid that maintains its rigid structure once manufactured a collapsible rigid box or foldable rigid box stays in a flat rectangular shape when manufactured. It is assembled during the final product packing stage by sealing the adhesive ends. These boxes provide excellent customization options when optimizing shipping costs and storage spaces.
Foldable rigid boxes use the self-assembly or foldability feature of mailer boxes but also benefit from the structure of a rigid box to provide a more high-end packaging solution. Manufacturing a collapsible rigid box requires more handiwork than a standard rigid box or a mailer box, which means that a foldable rigid box also costs more per unit. The question is, is it worth the extra packaging cost?
It certainly is. Let’s look at the key features to find out.
How does a collapsible rigid box work?
Collapsible rigid boxes are generally manufactured using a base grey-board or duplex board. This base material is coated with specialty paperboard for a bright print result.
Like standard rigid boxes, these boxes can be made from a variety of materials but the Mailer Box believes that the best material is the one that fits the customer’s specific packaging requirements.
The material is then cut flat using a pre-approved die-cut design and size. Once the units are cut, double-sided tape, instead of glue, is applied to the corners of the box.
You can discuss the various materials and their suitability for foldable rigid boxes with one of their packaging experts here at +1 801-783-4566.
When these boxes reach the final packing line, your packer can assemble and seal the box in seconds.
Once assembled, magnets installed in the top overlap of the box further secure the final closure. This eliminates the need for additional adhesives but you could add a paper sleeve for an extra oomph factor for your brand if you want!
What are Collapsible Rigid Boxes Most Suitable for?
Collapsible rigid boxes allow you to ship and store flat boxes as easily as custom mailer boxes. These boxes are sturdy and durable but bear in mind that they are not as strong as the standard two-piece rigid boxes.
The Mailer Box recommends using a collapsible rigid box for:
– Gift Packaging
– Health and Beauty Packaging
– Shoes and Handbags Packaging
– Apparel, clothes, and accessories packaging
– Electronic Product Packaging
These boxes can effectively hold products with a net weight of < 5kg. Items that are too heavy, e.g., tools and equipment, or heavy electronics are best packed in two-piece rigid boxes or custom mailer boxes with inserts.
A giant box of Lindt’s 27 chocolate bars isn’t something one can easily categorize – but a collapsible rigid box was a successful choice for that too!
These boxes are assembled using double tape which is strong enough for the items mentioned above but naturally has limitations primarily concerning the weight of items to be packed.
How do collapsible rigid boxes affect my shipping cost and time?
Collapsible rigid boxes allow you to save not only on volumetric shipping but also on storage space.
Approximately, you can store 4 collapsible rigid boxes in the space of one rigid box.
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How much more does a collapsible rigid box cost?
Luxury packaging such as rigid boxes can give your brand a significant facelift. These boxes are handmade and therefore cost more per unit than other types of packaging such as mailer boxes and shipping boxes, to begin with.
Collapsible rigid boxes are another step further from standard rigid boxes.
In the first step, the selected material is printed and die-cut. Then, magnets are installed to the inner base after which the rigid box is layered with a finishing coat of art paperboard or specialty paperboard.
In the second step, double tape is applied manually to the inner four corners of the box. The step is quite labor-intensive and makes collapsible rigid boxes more expensive than the standard rigid boxes.
You will be looking at an increase of $2 – 3 per unit with collapsible rigid boxes however, this additional cost becomes every bit worth it when you start reaping the benefits of 1000s of flat rigid boxes being easily stored in your production facility.
Are collapsible rigid boxes fully customizable?
Yes, manufacturing rigid boxes and collapsible rigid boxes is labor intensive, which not only gives them the ultimate luxury packaging experience but also makes them 100% customizable.
Lindt Chocolate came with unique requirements and The Mailer Box packaging was able to deliver the customizability till the last dot.
How can I achieve the perfect collapsible rigid box?
The key to achieving any perfect packaging solution is to partner with an experienced packaging partner such as The Mailer Box. The Mailer Box has a talented team and access to specialized packaging technology which enables them to provide you with the best packaging within the shortest lead time.
After your initial discussion about your packaging and design requirements, The Mailer Box team will send you a mock-up of your box die-lines. These would allow you to visualize your box as close to real as possible. If you require a sample or a prototype, that can also be arranged easily.
Once you have approved the box design and all the finer details have been finalized, the collapsible rigid boxes are sent for production and from there shipped to you anywhere in the world.
What happened to Lindt’s supersized milk boxes?
Lindt’s team got their customized collapsible rigid box at the doorsteps in the USA. The boxes were exactly what they envisaged. The crisp offset printing radiated luxury and brand power.
If you’re looking for a similar printing and packaging experience, contact The Mailer Box’s awesome team now at +1 801-783-4566.
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Ayesha Khubaib
Ayesha has a diverse experience in areas of marketing and management. Over the years, Ayesha has been involved in the packaging sector in various capacities and now aims to share packaging market insights with her readers
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