The Brand
Uncracked makes premium functional wellness shots across five SKUs: Hydrate, Glow, Immune, Repair and Detox. The packaging program covers custom spouted pouches, colored spouts and caps, and retail display boxes, across the U.S. and Thailand.
We started at launch scale. Working from their Pantone references, we matched color across the pouches, the spouts and the display boxes, and built the display to hold 167 mm in height excluding the tear-away backer, which had to work on a retail shelf, in a fridge, and on a sampling table. We expedited 400 boxes and 500 pouches for the launch window, and supplied 400 additional boxes at no charge to support it. The color came back accurate enough that the client filmed their own unboxing video.
The Challenge
Then distance became the problem. On long-distance distribution, the existing pouches were swelling and in some cases bursting, which capped the brand in the Bay Area. Scaling past, it meant moving to HPP to extend shelf life.
HPP puts packaging under immense hydrostatic pressure, and standard pouch films fail at the seal under it. That is a materials problem, and it sits in front of every retail conversation the brand wants to have.
Running two markets at once added a second layer. Five U.S. designs, three Thailand designs, different copy and regulatory versions for the same product, different spout counts, different delivery addresses.
The Solution
The HPP structure. We compared their standard MOPP / PET / AL / PE against a PET / AL / PA / PE structure built for high pressur2e, and shipped test pouches to both markets. HPP cannot be validated on empty pouches: it has to be tested with real product, real fill volume, real headspace and the actual equipment. We ran 300 MPa held for five minutes. The client ran 500 MPa for 180 seconds with actual product. Both passed with no leaks or seal failures.
The two markets. We reconciled every SKU, regional version and spout count across both markets, then arranged freight separately for each. Where spout colors were shared, we consolidated those production runs so the second market did not pay a duplicate setup fee.
The move to gravure. HPP's demands on material, ink, lamination strength, seal integrity and batch consistency pointed to gravure for the bulk run, and we kept the matte finish the brand wanted. Five designs came to 21 plates, reusable on every repeat order of the same design.
The pre-press. The Nutrition Facts panel read 65 g in one file and 85 g in another, so we had it confirmed to one number across all five. The nutrition labels had been generated online as PNGs, with type fine enough to blur on an engraved cylinder, so we rebuilt them as press-ready files and confirmed copy, color and detail before any plate was cut.
The Result
50,500 HPP spouted pouches into production, on a structure validated at pressure in two countries with real product inside it.
A brand that could not ship past the Bay Area now has packaging that travels.
"Dylign didn't just design our pouches, they helped us solve the HPP engineering needed to scale internationally."
