How DHP Factory Crafted the Perfect Eco-Friendly Packaging for Premium Tea Brands | DHP Factory Customized Gift Box Industry Cases

Client Background

Tea Lab Company is a UK-based premium tea brand known for its strong focus on sustainability and creative presentation.

The brand packages its tea in glass test tubes and bottles, creating a distinctive “lab-inspired” unboxing experience that reflects its product philosophy.

· Industry: Premium Tea & Beverage

· Market: United Kingdom

· Project Type: Eco-Friendly Rigid Gift Box

· Key Materials: Art Ultra White Card, Greyboard Insert

· Key Requirements: No Lamination, CMYK Printing, Glass Protection

· DHP Factory Role: Structure Design, Material Selection, Insert Engineering

Client Challenge

Tea Lab Company sought an eco-friendly packaging solution that could meet the following requirements:

• The box must be fully eco-friendly, with no lamination

• A clean white appearance with CMYK printed borders for visual detail

• Secure protection for fragile glass test tubes during shipping

• Textured finishes required on both the box exterior and the insert

This project required balancing sustainability, print quality, and structural protection within one packaging solution.

Our Packaging Solution

After reviewing the client’s design vision and functional requirements, DHP Factory developed a packaging solution driven by material performance and structural stability.

Paper Selection:

We selected Art Ultra White Card to achieve the client’s requirement for a high level of whiteness and excellent CMYK print performance.

Although this paper has a naturally smooth surface, embossing was applied to create the desired tactile texture without using lamination.

Insert Protection:

To protect the glass products, a thicker version of the same ultra-white card was embossed and mounted onto greyboard.

This construction significantly improved insert strength while maintaining a consistent visual and tactile appearance.

Fit and Stability:

Custom die-cut slots were precisely adjusted to ensure each glass tube remained securely in place, preventing movement during handling and transportation.

Production Details

Material:

Art Ultra White Card with embossed texture

Box Structure:

Two-piece rigid box with CMYK printed border

Insert:

Greyboard-backed embossed paper insert for enhanced protection

Finish:

Eco-friendly unlaminated construction with embossed texture on both box and insert

Result & Outcome

The final packaging solution successfully met all eco-friendly requirements while delivering strong product protection and refined shelf presentation.

The embossed texture enhanced the unboxing experience, and the custom insert design ensured the glass products remained stable during transportation.

The client expressed high satisfaction with both the packaging quality and the overall brand presentation.

Why This Case Matters

This case demonstrates how a manufacturer-led approach to material selection and structural design can achieve sustainability, functionality, and premium presentation in one packaging solution.

By prioritizing eco-friendly materials and precision engineering, DHP Factory helped transform a complex set of requirements into a practical and scalable packaging outcome.