The Brand
Lauren founded Big Little Pies to bring freshly baked, hand-crafted mini pies straight to people's doorsteps. The pies travel inside individual baking tins, which means corrugated mailers with divider inserts sized for 4-pack, 8-pack and 12-pack sets.
She also wanted the box to do more than protect. A soft pink interior, and the line "and butter" printed inside the lid, so the shipper becomes part of the brand experience rather than the thing the brand arrives in.
The Challenge
Lauren had her design as Canva images. There was no way to map those images accurately onto three different box structures, and no clear answer to what the print would cost, since where a line of copy sits determines whether a box needs single-sided or double-sided printing, and that decision moves the price after the design is already approved.
The Solution
The files. We rebuilt her Canva concepts into production-ready artwork, mapping the layouts onto each box structure. Where "and butter" sits, inside the lid or on the flap, decides whether a box needs single or double-sided printing, so we settled those positions with her before the cost showed up as a surprise.
The sample. Print quality passed. Two things did not: the 12-pack came in at 2.25 inches instead of 2.0, and the laminated corrugated frayed slightly at the fold corners. The height was our error. We remade correct samples in 3 days against a 7-day standard, and adjusted score-line clearances and folding tolerances to stop the fraying. Lauren tested the new sample with real product and confirmed the lower profile held the tins better.
The run. Three sizes at 1,000 each, double-sided, pink interior and lid copy across the range. When her bank mailed a physical check and clearing time threatened the schedule, we started production before the payment landed.
The delivery. We sent dimensions, counts, volume and weight for all 85 cartons so she could plan warehouse space. Mid-ocean she needed the destination changed. We coordinated the intercept, explained the odds and the cost, and all 85 arrived at the new address on August 11.
The Result
3,000 mailers across three pack sizes, a 12-pack that fits the tins properly, and clean corners on a laminated board that was fraying two rounds earlier.
The work did not stop when the boxes came off the line. It stopped when they reached the right warehouse.
“Dylign stayed with us from the first Canva file to final delivery.”
