Discover our unique retail packaging solution that combined complex carton engineering with an innovative hinged insert design.
Project Overview
We were approached to develop a unique retail carton and insert solution for the Coastal Living Melt Warmer range.
The packaging needed to display a melt burner, four scented melts, and a tealight candle within an unconventional trapezoidal carton design. The melt burner needed to be showcased through a front aperture, while the melts were required to sit neatly on either side of the carton to create a balanced and premium retail presentation.
Key Design Features
Bespoke Trapezoidal Carton
A specially developed carton structure designed around an unusual angled shape, creating a distinctive retail presentation.
Front Aperture Display
The carton design allowed the melt burner to remain visible, improving shelf appeal and product presentation.
One-Piece Flexible Insert
A single-piece insert designed reduced assembly complexity while providing secure product retention.
Integrated Hinge System
Multiple hinges enabled the insert to fold and adapt perfectly to the carton’s complex geomtry.
Double-Back Retention Design
The insert folded back on itself to hold the melts flush against the angled side panels.
Prototype-Led Development
Five carton revisions and multiple insert trials were completed before production approval.
The Challenge
The unusual trapezoidal carton shape presented a number of technical challenges, as it differed significantly from conventional carton formats previously produced.
The main challenge was developing an internal support system that could securely hold the melt burner and melts in position while following the angled sides of the carton.
The insert needed to provide:
- Secure product retention.
- Protection during transport.
- Accurate positioning of multiple components.
- A premium retail appearance.
Our Development Process
We carried out an extensive prototyping process to identify the most effective solution.
Several concepts were designed and tested, including:
✓ Cardboard structural inserts
✓ Single skin plastic inserts
✓ Double skin plastic inserts
✓ Alternative carton constructions
The carton design was modified five times from the original concept to ensure the final structure performed correctly and could be manufactured efficiently.
The Solution
The final solution was a bespoke one piece flexible plastic insert incorporating multiple integrated hinges.
The hinged construction allowed the insert to fold into the required trapezoidal shape while maintaining strength and stability. The insert also doubled back on itself, creating a secure support system that held the melts flush against the angled carton sides.
This created a packaging solution that combined:
- Innovative structural design.
- Secure product positioning.
- Premium retail presentation.
- Production reliability.
The Result
The finished packaging successfully achieved the customer’s objectives and was approved for production.
The final solution delivered:
✓ A unique retail presentation format
✓ Secure retention of the melt burner, melts and tealight candle
✓ Improved shelf presence through the front display aperture
✓ A practical insert design suitable for manufacturing
✓ Successful production and delivery to the customer
Innovation
This project demonstrated ABC Packaging Ltd’s ability to develop solutions for complex packaging challenges.
By applying advanced folding techniques, integrated hinges and push lock features, we created a flexible insert capable of forming and supporting a complex three-dimensional structure.
This approach provided valuable insight into how engineered carton and insert combinations can replace conventional solutions while maintaining product security and presentation quality.
Why ABC Packaging?
Here at ABC Packaging, we specialise in developing bespoke packaging solutions that combine creative design with practical manufacturing expertise.
From initial concept and prototyping through to production, we help customers overcome challenging packaging requirements and deliver solutions that protect products, improve presentation and add value.