The Brief
Chivas Regal required a hybrid carton that combined the presence of a rigid box with the efficiency of a folding carton. The structure had already been developed, but the challenge was to reproduce the pack to the same visual and structural standard, and to run it reliably at production scale in the UK.
The Challenge
Hybrid cartons of this style are complex to manufacture and require tight control across printing, foiling, cutting and gluing to ensure the pack erects correctly and maintains a premium appearance. The combination of decorative finishes, structural accuracy and packing line performance meant the carton had to be produced with absolute consistency. Running this style of pack at speed without compromising finish quality was a key requirement.
The Solution
Beamglow worked closely with material suppliers and used premium solid board from Billerud to ensure the structure performed correctly and maintained its rigid appearance once formed.
Specialist in-line cold foil and finishing techniques were used to achieve the decorative standard required, supported by presses configured specifically for this type of work.
Close control across print, tooling , construction and gluing allowed the hybrid structure to run efficiently while maintaining the premium finish expected for the Chivas Regal brand. The finished cartons were supplied fully constructed in cases, ready for efficient packing by Chivas Regal’s packing partner.
Key Highlights
- Delivered fully erected and ready for bottling
- Packed locally and delivered ready-to-fill, reducing transport and CO₂ emissions
- Supplied as a finished pack direct to the bottling line
The Result
The finished pack delivers the appearance of a rigid box with the efficiency and sustainability benefits of a folding carton. The cartons run reliably during packing, maintain structural integrity in transit, and deliver the high-quality finish expected from a global premium whisky brand.
