The Brand
Yaupon is North America's only native caffeinated plant, wild-harvested across the American South and brewed into a smooth, clean tea. Andrew Little started Goldholly to bring it into daily routines, selling loose leaf in rigid paperboard cartons. The team sits across London, Boston and Philadelphia.
The Challenge
The cartons cost too much to ship, took up too much shelf, and did nothing to protect the tea's delicate aroma from moisture and oxygen. Andrew came to us with three requirements at once: a clear window so shoppers could see the loose leaves, PCR content in the structure, and maximum barrier protection. In flexible packaging, those three pull against each other. On top of that, with a team in three cities, every sample review had to happen in three places.
The Solution
We engineered a mono-material PE structure: a matte PE outer layer for crisp printing, a metallized layer for barrier, and a PE sealant layer carrying the PCR content, so the whole pouch stays in one recycling stream. The window was the harder half. A metallized layer is what stops moisture, oxygen and light, and it is also opaque, so you cannot cut a window into it without cutting a hole in the barrier. We applied selective demetallization, removing the aluminium only over the window zone while the structure stays intact everywhere else.
The Result
A pouch with recycled content, a clear window, and the barrier the tea needs, backed with full technical documentation including barrier test data and regulatory compliance reports. We produced press-accurate physical samples and dispatched them to London, Boston and Philadelphia at the same time rather than passing one set around. Within fourteen days, every team member had samples in hand for final approval.
“We gave Dylign a tough brief—and they delivered.”
