One Chocolate Brand. Two Packaging Needs. Eight SKU Designs.
A Minnesota-based chocolate brand needed custom packaging for two different parts of its business: presenting products in retail environments and preparing branded packaging for shipped orders.
The project involved 800 boxes across eight SKUs, with six retail-display variations and two mailer-box variations.
The customer supplied a logo and product information but needed BoxBaba to develop production-ready packaging artwork, prepare the required box layouts and coordinate multiple variations through production.
Project Overview
Customer: Minnesota-based chocolate brand
Location: Duluth, Minnesota, USA
Project: Retail display and mailer packaging
Quantity: 800 boxes
SKUs: 8
Display Boxes: 600 across 6 SKUs
Mailer Boxes: 200 across 2 SKUs
Display Material: 22 pt SBS paperboard
Mailer Material: Corrugated board
Printing: 4/0 color printing
Finish: Matte lamination
Artwork Revisions: 4
Delivered: January 29, 2026
The Challenge
The customer needed packaging for two different applications.
The first requirement was retail presentation. Six product variations needed packaging that could organize and present the chocolate products in a retail environment.
The second requirement was shipping. Two additional product variations needed corrugated mailer packaging suitable for the brand shipping workflow.
The project therefore had to coordinate:
- Two different packaging structures
- Eight SKU-specific designs
- Different box dimensions
- Retail and shipping requirements
- Customer-supplied branding
- Production-ready artwork development
- Multiple design revisions
The customer had the logo and product information but did not provide completed packaging layouts ready for production.
The Packaging Solution
BoxBaba developed two packaging formats for the project.
Retail Display Packaging
The first part of the order included 600 custom perforated auto-lock retail display boxes across six SKUs.
Each SKU included 100 boxes.
The display-box specification included:
- Dimensions: 6.25 × 4.6 × 3.1 in
- Material: 22 pt SBS paperboard
- Printing: 4/0 color printing
- Finish: Matte lamination
- Structure: Perforated auto-lock display format
The display packaging provided a dedicated format for presenting the chocolate products in retail settings while allowing each SKU to retain its own artwork.
Corrugated Mailer Packaging
The second part of the order included 200 custom mailer boxes across two SKUs.
Each SKU included 100 boxes.
The mailer specification included:
- Dimensions: 6.1 × 3.1 × 1.25 in
- Material: Corrugated board
- Printing: 4/0 color printing
- Finish: Matte lamination
Together, the two packaging formats created a coordinated solution for both retail presentation and shipped orders.
From Brand Assets to Production-Ready Packaging Artwork
The customer supplied the logo and product information, while BoxBaba design team developed the packaging layouts around those materials.
Support included:
- Box outlines and dielines
- Artwork layout development
- SKU-specific packaging graphics
- Production-file preparation
- Coordination across both packaging structures
Rather than requiring the customer to provide finished packaging artwork, the project moved from supplied brand assets to production-ready box files with assistance from the BoxBaba design team.
Four Artwork Revisions Without an Additional Design Charge
The project involved four artwork revisions.
These revisions were completed without an additional design charge.
This allowed the customer to refine the packaging presentation across the eight SKU variations before the designs proceeded to production.
Because the project included multiple products and two different structures, keeping the individual designs organized was an important part of the workflow.
Production and Quality Assurance
The order was placed on:
January 15, 2026
The project record shows a five-working-day production period.
Production was recorded as complete on:
January 22, 2026
A dedicated quality-assurance stage followed on:
January 23, 2026
The exact courier dispatch date was not recorded, so no unverified shipment date is stated here.
Delivery to Duluth, Minnesota
The completed order was delivered to:
Duluth, Minnesota
on:
January 29, 2026
The final delivery included all 800 boxes across eight SKU variations.
The Result
The project delivered two coordinated packaging solutions for a growing chocolate brand:
- Retail display boxes for six SKUs
- Corrugated mailer boxes for two SKUs
The final order totaled 800 boxes, providing the customer with packaging for both retail presentation and shipping requirements.
The project also included complete artwork preparation and four no-charge revision rounds, allowing the brand to move from supplied logo and product information to production-ready packaging across eight individual designs.
No unsupported claims about sales growth, conversion rates or shipping-damage reduction are made because those outcomes were not measured as part of the project record.
Project Highlights
800 Total Boxes
Produced across eight SKU-specific variations.
6 Retail Display SKUs
600 perforated auto-lock display boxes for retail presentation.
2 Mailer SKUs
200 corrugated mailer boxes for shipped orders.
22 pt SBS Display Boxes
Used for the six retail-display variations.
4/0 Color Printing
Specified across both packaging formats.
Matte Lamination
Applied to the display and mailer packaging.
Complete Artwork Support
Packaging layouts were developed from customer-supplied branding and product information.
4 No-Charge Revisions
Four artwork revisions were completed before production.
Coordinated Production & QA
Production was completed on January 22, followed by a dedicated quality check.
Need Packaging Across Multiple Products or SKUs?
If your business needs different packaging formats across multiple products, BoxBaba can help organize the structures, artwork and production requirements for the project.
For chocolate and confectionery brands, explore our custom chocolate packaging options.
When requesting a quote, please provide:
- Product dimensions
- Number of SKUs
- Quantity required for each SKU
- Preferred packaging styles
- Logo and artwork files
- Printing requirements
- Finishing requirements
- Delivery location
- Required timeline
Ready to discuss your project? Request a custom packaging quote and share your packaging requirements with the BoxBaba team.
Recommended image caption:
Representative BoxBaba display and mailer packaging mockup illustrating the project structures; not the customer original packaging photography or brand artwork.