The Brand
Tuyyo Foods brings Latin heritage flavors into modern kitchens, and the lineup is unusually wide for a brand at this stage: snack pouches, seasoning sachets, Agua Fresca powder stick packs, 20-count multi-pack stand-up pouches, four flavor cartons, and retail display cases.
Six formats, different materials, different production processes, different sales channels. The team is also spread across three states.
The Challenge
Handled one at a time, six formats become six separate projects with six separate specifications, and nothing carries forward when the next SKU launches.
The hardest one is the Agua Fresca multi-pack. Twenty stick packs come close to a pound, and a pouch carrying that weight has to stand upright on a shelf without sagging, which is a structural problem before it is a graphics one.
There was a materials question underneath all of it. Snacks and seasonings touch the packaging directly and need maximum shelf life protection. Stick packs are already protected inside their own wrapper, so the outer pouch can be lighter. And the brand wanted recycled content it could talk about in its marketing.
The Solution
The material test. We shipped physical samples in a range of thicknesses and structures to team members across all three states. They handled them, filled them, and told us what worked and what felt too thick. We turned that into material parameters.
The structure. For the Agua Fresca pouch, we calculated load-bearing capacity and gusset dimensions against a near one-pound fill, then adjusted height, width and gusset against the client's testing and co-packer feedback until the fit was snug with no excess volume.
The barrier. We compared foil, VMPET and EVOH across oxygen barrier, moisture, light, recyclability, hand-feel and cost. EVOH works where stick packs provide their own protection; direct-contact products need more. The client chose MOPP / VMPET / PE.
The PCR and the claim. We added a 30% PCR-PE layer alongside the VMPET core, then told them what they could not say: a multi-layer structure cannot be marketed as “30% recycled plastic” overall. We proposed accurate wording instead.
The execution. Digital printing across the SKUs, so plate fees do not multiply with every format. 240 matte snack pouches expedited for Summer Fancy Food Show, and unprinted white structural samples for the October HEB submission, scheduled alongside dimension confirmations, dieline updates and carton proofs.
The Result
Six formats running on one set of decisions rather than six, with the structure, the barrier and the sustainability language all settled before the retail submissions went in.
“Dylign helped us find the right balance between packaging performance and brand experience.”
