Antalis Packaging showcases its premium packaging expertise with chocolate egg mailer

Packaging Solutions

Antalis Packaging has demonstrated the capabilities of its recently launched Premium Packaging service by developing a direct mail campaign that combines structural design, premium materials and sustainable packaging to safely deliver a fragile chocolate egg while creating a memorable customer experience.

Created entirely in-house, the project was designed to showcase how the company can support customers through every stage of the premium packaging journey from concept and material selection through to structural design, production and fulfilment.

Delivering a chocolate egg through the postal network presented an ideal test. The packaging needed to provide product protection while creating an engaging unboxing experience, reflecting the customer's brand values and remaining practical to manufacture, assemble and recycle.

The finished mailer comprised three bespoke packaging components, each designed to perform a specific role.

The chocolate egg was housed within a custom designed moulded pulp egg box, chosen for its shock absorption properties. The pulp insert incorporated an integrated locking closure to secure the product during transit, while remaining fully recyclable and biodegradable.

The moulded pulp insert was then presented inside a bespoke presentation carton manufactured from Keaykolour Lipstick 300 g/m2. The carton featured distinctive curved profiles, layered structural folds and an innovative glue free locking design, demonstrating how cutting and folding techniques can eliminate adhesives whilst producing a premium finish.

Printed digitally on an HP Indigo 1200, and precision cut using a Kongsberg X24 digital cutter, the carton also illustrated how striking visual impact can be achieved using a simple single colour print process. White graphics printed onto the coloured board created a tactile finish while maximising the branding space of the pack.

The presentation carton was then enclosed within a bespoke e-commerce mailing box manufactured from lightweight E-flute board, from Antalis. Designed around the dimensions of the presentation pack, the outer carton eliminated the need for void fill while incorporating a peel and seal closure and tear strip for quick fulfilment and an enhanced opening experience.

Sustainability remained central throughout the project. The moulded pulp insert is recyclable and biodegradable, the Keaykolour board is FSC certified with an Antalis Green Star rating of 3, and the outer e-flute carton is manufactured from sustainably sourced fibre and is fully recyclable. By engineering each component to perform a specific function, the team also minimised material usage and reduced the overall distribution footprint.

Emma Brown, premium packaging lead, said: ‘Businesses are looking for much more than a packaging supplier. They want a partner who can help them balance creativity, sustainability, operational efficiency and customer experience. Antalis’ Premium Packaging service brings all those disciplines together under one roof, enabling customers to move from an initial idea through design, prototyping, production and fulfilment with a single trusted partner.’

Verity Mottram, creative design lead, added: ‘Using a chocolate egg gave us the perfect opportunity to demonstrate how structural packaging design can solve a genuine logistical challenge whilst still creating a memorable brand experience. Every design decision was carefully considered, from the protective moulded pulp insert through to the presentation carton and e-commerce box, ensuring the packaging delivered on protection, sustainability, ease of fulfilment and visual impact.’

The Antalis Premium Packaging service provides customers with a complete turnkey solution, covering structural and graphic design, material selection, sourcing, prototyping, production, stock management, UK fulfilment and distribution. By combining creative expertise with technical knowledge and an extensive portfolio of premium materials, the company helps brands create packaging that not only protects products but enhances customer experience and delivers measurable commercial value.