Our award-winning packaging is a testament to our capabilities and dedication in support of client partnerships to develop creative, cutting-edge, and environmentally friendly folding cartons, promotional packaging and rigid boxes that truly ‘Presses the Limits’.

We’ll take a closer look at each of these award-winning packages to provide insight on our client collaborations as a go-to premium packaging provider for leading national and global brands.

Goose Island Bourbon Stout 30^th Anniversary

Gold Award: Sustainability, Innovation

Goose Island Beer Company, a Chicago brewery named after a nearby island and pioneer of bourbon barrel-aged beer, granted us the opportunity to produce the package to showcase the 30th anniversary of their Bourbon County Stout.

While providing samples to drive inspiration, our client ultimately decided that a two-piece side loading slipcase and tray would provide the most unique package. We designed a structure that included windows on the front and back to showcase the 16.5 oz. Bourbon County Stout. To create a unique unboxing, we crafted a creative concept that featured a die cut image of the bottle on the left side of the slipcase for end users to push the tray open and slide out the inner carton.

Our collaboration for the 30^th Anniversary of the Bourbon County Stout resulted in a highly decorated paperboard structure.

• Printed on a 24pt stock, utilizing 4-color process, (2) PMS inks, and gold foil stamping throughout to create contrast.
• The look of charred barrel on the interior structure was designed using soft touch, spot gloss, and emboss patterns to create a wood grain, tactile feel.

The stock included 10% PCW, the brand’s 30^th anniversary paperboard package is sustainable and fully curbside recyclable.

Freixenet Mionetto’s Holiday Advent Calendar

Gold Award: Innovation

Freixenet Mionetto USA is one of the largest sparkling wine companies with global success drawn from an equal blend of quality, passion, and innovation.

The brand called on us to manage the production of their holiday program; an advent calendar that would house 12 of their specialty crafted sparkling wines. Freixenet specified the need for quick turnaround and a cost-effective design that would allow for flexibility of product placement.

Our structural engineers developed prototypes based on creative concepts the brand desired: a structure that resembled a Christmas tree. While the concept would pose more challenges than that of a standardized, rectangular structure, the tree format was viewed as more of a unique structure that embodied the spirit of the holiday season.

Our development team improved the overall design by compressing the concept’s initial size, ensuring sustainability while continuing to support the project’s creative integrity. We also recommended an additional panel for the outer carton to serve as a protective layer for avoiding potential tampering in the retail setting.

Due to the size and weight of the package, it was designed to be ergonomically carried by the handle for ease of transport by the consumer. Retailers were also able to stack the individual Christmas tree package to form an in-store Christmas tree.

Florence by Mills Advent Calendar

Gold Award: Sustainability

florence by mills is a brand made with love by Mille Bobby Brown (the well-known Stanger Things actress, also known as Mills.) Her brand was looking for a new domestic supplier for their Peace, Love, and Florence advent calendar in time for the holiday season. While quick turnaround was an essential priority, the calendar also needed to be high quality to reflect the clean, non-toxic qualities of the brand.

Our structural engineering team worked with florence by mills team to develop a fun, colorful, and interactive 12-day advent calendar featuring their skincare and cosmetic products as well as an ornament for the last day in individual cartons nested inside of a keepsake box.

The finished package includes:

• FSC stock used throughout the package.
• Fully recyclable and biodegradable materials.
• A keepsake box that can be repurposed and is reusable.

Lancôme Holiday

Gold Award: Sustainability

For the 2022 Holiday season, Lancôme was looking to create a package that would showcase an intricate flower pattern created by one of their designers in France . A digital comp of the pattern was provided for reference for our team to begin developing a luxury packaging solution including folding cartons and rigid boxes that also needed to be fully recyclable.

To achieve this, we:

• Translated the pattern into multi-level embossing creating a microetched effect combined with matte and gloss coatings to add dimension and fine detail.
• Used gold, silver and rose gold foil cold foil for the packaging and hot stamping for the inner paperboard trays.
• As part of L’Oréal’s commitment to sustainability, FSC paperboard and chipboard were used along with paperboard trays to replace traditional thermoform tray, making the entire package recyclable.

The entire packaging line also features a very detailed and dimensional rose pattern across the set of 9 rigid boxes with sleeves and 18 folding cartons.

Urban Decay ‘She Hulk’ Folding Carton

Gold Award: Innovation

Urban Decay teamed up with Marvel Studios to promote the new comedy series, She Hulk, now streaming on Disney+. The promotional kit helped fans get ready for the show’s premiere by releasing a limited edition set of one of their “hero” SKUs – the iconic, All Nighter Setting Spray with expandable sponge.

We engaged the Urban Decay team with ideas on how to best execute their desired decorative embellishments while providing cost saving solutions. Our team developed a plan to explore different finishes and printing techniques that would maintain the creative integrity of the client provided artwork.

Ink drawdowns and technical findings were provided to our clients to better understand the benefits of hot foil vs. cold foil while using a 4-color process to enhance the print.

An 18pt stock was selected to provide a premium feel package that was also lightweight. Stabilizers were added to the bottom of the carton to provide on-shelf stability. Featuring rainbow holographic hot foil stamping, multi-level embossing and a matte and gloss finish, the unique decoration on this paperboard folding carton really packs a punch!

Diageo Tanqueray Gift Box

Excellence Award: Innovation

As part of helping our partners boost their visibility in the marketplace, JohnsByrne provided support to the Tanqueray brand by developing an interactive, 2-piece carton for Diageo to gift to influencers and distributors. Both teams collaborated from concept to completion to develop this unique and impressionable packaging design: a vertical telescoping SBS box with a flower layflat reveal.

We worked closely with the customer to fit the artwork and the special challenges the flowering base created for art crossovers.  Use of tone-on-tone blind spot gloss UV on the base creates a modern look.

doTERRA Malama Holiday Kit

Excellence Award: Innovation

Our clients at doTERRA came to our team with an ask to manage their Malama Collection Holiday rigid box with an overwrap, insert tray, and carton.

We worked with the client to develop this creative concept as they were looking for a structure and enhancements that would bring the packaging to life.

To provide a premium unboxing experience for the 3 kit SKUs, the structure was wrapped and lined with a magnetic closure and featured tactile finishes including an overall soft touch and foil stamp throughout the design.

Visit JohnsByrne.com to learn more about our sustainable packaging solutions and innovation process for collaborating with clients to understand their brand direction, product vision and desired high-impact result. From our innovative structural design and sustainable packaging solutions to our robust printing and finishing capabilities, we look forward to continuing to ‘Press the Limits’ with our clients to help them be successful and build their brands.

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When we revolutionized the industry in 2014 with our one-of-a-kind 15-unit Press 384 – in JohnsByrne’s Limitless Pressroom – our goal was the highest consistent quality printing combined with new levels of responsiveness. A change for the better. 

We continue to invest in people and technology to drive our success as well as the success of our customers. Since then, we have added additional machines that bring what we promise customers – speed to market, excellent quality, and innovation. When looking for the right equipment to add to our press room, we continuously search out the latest technology and are excited about the newest printing and packaging capabilities. Here is the story behind one of our latest additions – our ‘Press the Limits’ Continuous Improvement mantra is about to unveil another change: for better sustainability and better response to fundamental business conditions and customer demands.  

In June, we will bring our brand new, CO2-neutral, Heidelberg Speedmaster XL 8+L eight-color press online. This new press complements our comprehensive in-house printing and finishing technologies. Leveraging both AI and big data, it is simply the most energy-efficient, highly automated press available today. And it’s designed specifically to address the confluence of two most-critical concerns facing our industry today: sustainability and speed-to-market. 

Sustainability first. Ambitious sustainability initiatives amongst the world’s major brands – from Coca-Cola to Coors, Nestle to Walmart – are driving the trend to replace plastic with paper / cardboard as consumers’ eco-friendly demands rise.  

Recognizing the impact of CO2 emissions on climate change, our new press actually offsets the environmental cost of building it: Heidelberg utilizes a formula to determine total greenhouse gas emissions, then purchases “certificates” representing carbon offset by planting trees which soak up the CO2. In this case, 2,318 trees in a sustainable Gold Standard reforestation project; roughly 7.6 soccer pitches-worth of trees, making JohnsByrne one of only four fully carbon-neutral printers in North America.  

In operation, the new press will continue to contribute, given that the faster it runs, the more energy it saves per 1000 printed pieces. In fact, energy efficiency gains since the 1990s mean in operation, the press will double the Kyoto requirements of improvement in efficiency: an astonishing 41.7% energy savings. 

Streamlined Operator Independent Performance 

Now, about speed-to-market. The new Speedmaster’s clear focus is on “operator independent performance,”  

Leveraging AI, big data, and digital process integration, the new press will run faster, more reliably and consistently, with far less direct operator interaction: termed “operator-independent performance.” In short, a way-smarter press that delivers better throughput, total process optimization, improved uptime, reduced waste and, of course, superior print quality. Our human capital and highly trained operators are key to success in the manufacturing process. We have continued to attract and develop talent and like to think of our facility and our pressroom as a hub of applied technology that is constantly evolving for the better.   

The User Experience (UX) of this new press is totally redesigned to accommodate the specific skill level and training of the operator at the console. In that sense, this revolution in printing is as much about software as hardware.  

Adapting press functionality to pressrun needs and operator skill levels, it deactivates functions based on specific operator experience, limiting mistakes and the chance incorrect settings are carried over from run to run. In addition, the operating system delivers continuous visualization of the entire press… just the right information at the right time, presented clearly and intuitively.  

Big Data from over 180 reference presses and 300,000 jobs were assimilated to create optimized characteristic curves for press settings; including presets, powder assist and wash assist. Combined with LED indicators on every stand to continually report process status and possible issues requiring manual intervention, better throughput is assured thanks to shorter makeready and fewer errors and stoppages. 

Meanwhile, a host of automated quality assists translate to more accurate, more uniform results, including: 

• Faster paper white and ink zone measurements at the start of the job  
• Automated measurement of register directly after the first color measurements 
• Optimized color control  
• Automated quality measurements (dot gain, etc.) every 400 sheets  

Consider that 80% of print inking problems are related to incorrect roller settings in the dampening unit. This system utilizes remote control of pressure settings for more stable ink/water balance, minimal risk of emulsification and early identification of anomalies. So one operator can see all the roller settings from one location, even while in another room. 

The new press is designed with features that provide near-continuous pre-loading, loading, automated non-stop operation, and fully automatic non-stop delivery of printed sheets. All this print quality automation delivers genuine speed-to-market improvements as promised. 

And, because it includes press-specific, real-time maintenance management and documentation software, Heidelberg can monitor press performance and predictively troubleshoot on demand. It can monitor motor temperatures, for example, evaluate probable causes and prompt operators to take action before an anomaly can affect print quality or cause damage. Less downtime, more printed sheets. 

In one sense, JohnsByrne‘s Limitless Pressroom environment is as much a laboratory as a high-tech factory floor. And, joining several other brand-new additions, the new press will provide a new level of repeatable quality and continue to advance our strategic, vertically integrated business model: a true end-to-end solution that defies supply chain disruptions as it provides single-source accountability, superior quality and distinct competitive advantage to our customers.  

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The company’s winning package, Kiehl’s Advent Calendar for 2020, took two awards in the competition – not only the top “Package of the Year” honor but also won the Gold Award for Sustainability. In addition, JohnsByrne also won a Gold Award for Achievement in Packaging for the Case Makes Swatch Kit and an Excellence Award in Packaging for the Rabbit Hole Rigid Box. The packaging designs recognized in PPC’s competition represent some of the year’s best folding cartons and rigid boxes.

“Not surprisingly, Kiehl’s has a cult-like following of customers dedicated to their products,” stated Corey Gustafson, president of JohnsByrne. “The Advent Calendar is a special celebration with feature artists, products and designs. You can actually see the love customers have for the Calendar in unboxing videos and linked social media posts that many people have posted on their own!”

This is the 7th Advent Calendar by JohnsByrne for Kiehl’s. The challenge: to create a calendar that not only provided an extraordinary consumer holiday experience but for the first time was made of 100% recyclable materials to embody Kiehl’s commitment to sustainable packaging, and its “Future Made Better” journey theme. Result: a luxurious, intricate Advent Calendar made entirely of sustainable materials, and without the plastics traditionally used in such packages…the greenest holiday campaign ever.

The design – representing a whimsical visit to a Kiehl’s store – includes 24 Kiehl’s products in individual straight-tuck cartons, designed for a snug, puzzle-like fit inside the outer hinged box. So not only does the enclosing box double as a shelf display, but the individual boxes also offer a premium unboxing experience… and the entire Calendar can be reused.

“The Calendar encompasses everything Kiehl’s required from us in this annual showpiece and more, including sustainability, stunning graphics and an unboxing experience like none other for the customer,” added Corey Gustafson. “Annual production has tripled since our first Calendar for Kiehl’s seven years ago and has included amazing enhancements each year. This is the type of challenge our structural engineers excel at meeting, and we are thrilled to be awarded Package of the Year.”

No wonder this collectible sells out early every year, and customers keep their Advent Calendars long after the holidays are over.

“The 2021 competition was fierce, highlighting not only the expertise and virtuosity of PPC members but also the sustainable nature and limitless creative possibilities of paperboard,” according to the 2021 Panel Award Judges. Regarding the Kiehl’s Advent Calendar designed by JohnsByrne, the judges noted the sustainability emphasis: “They replaced the inner vac tray from previous years with these beautiful boxes and graphics to tell the story for the countdown to Christmas.”

About JohnsByrne Company

JohnsByrne is a premium packaging and custom print company specializing in folding carton, specialty packaging, point-of-sale, and high-impact direct mail solutions. Since 1959, JohnsByrne has diligently maintained the company’s vision of providing superior packaging and print solutions in a client-driven company culture. With strict adherence to processes and the latest equipment technology, JohnsByrne creates customized and invented packaging and printing solutions with single-source accountability. Learn more about sustainability packaging with JohnsByrne and start your innovation consult today.

To learn more about PPC and the North American Paperboard Packaging Competition, visit paperbox.org.

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Recently, JohnsByrne circled back to answer that two-part question again, this time by simply “doing the math.” And as you’ll see, having the math on your side is a powerful advantage in today’s supply-chain-challenged world.

384 – THE ONLY 15-UNIT PRINTING PRESS

JohnsByrne is home to Press384, the only 15-unit printing press in the country. Consisting (at the moment) of 3 coaters, 8 print units and 4 dryers in-line, it’s G7-certified and compliant. And it’s only 1 of 5 presses in “The Limitless Pressroom.”

You might not think of a pressroom as a laboratory but JohnsByrne does. Another reason why we bring such high levels of innovation to our customers, combining art and technology to create multisensory brand experiences for the consumers who touch our customers’ brands.

The way we see it, the real challenge is to imagine and manipulate unique sequences of coating, printing and drying to create never-before-seen product packaging. Adding value – and brand value – are JohnsByne’s variety of press technologies, creating new materials out of coatings and paper, then printing on it, then finishing it, all in 1 pass, all on 1 line.

4 + 5 – LARGEST SPECIALITY PACKAGING IN THE MIDWEST

That would be 4 foil stampers and 5 die cutters: the largest assembly of die-cutting and foil stamping in the Midwest. For manufacturing at scale, there’s just no equal.

24/7 – PRODUCTION RUN TIME

Keeping up with the market and staying ahead of the competition is crucial for any brand. Keeping up with some of the world’s most prestigious – and persnickety – brands is what JohnsByrne is all about. So naturally, our domestic production facility is up and running 24 hours a day, 7 days a week. (Stop by anytime).

50 – MADE IN THE USA

States in the U.S.A. and no matter which one you’re in, you’ll enjoy easier access, more thorough collaboration and faster shipping for every project. Because every JohnsByrne project is proudly made in the U.S.A. And another reason why, as global supply chains continue to challenge production that depends of outsourced components, JohnsByrne can offer profound competitive advantage as a speed-to-market innovator.

1 TO 1 – DIRECT MILL RELATIONSHIPS

As in, 1-to-1 mill-direct relationships. Ours go back decades with leading domestic suppliers, and personally involve company leadership. Our goal is “vendor partners”: we take the time to understand their businesses and help them understand ours. That investment in vendor/partner relationships – plus ISO level accountability, prompt payment and fair treatment – has really paid off right now, putting JohnsByrne in an advantageous position as supplies have gotten so tight.

Simply put, when you take care of your vendors, they’ll work harder to take care of you. For our customers, partnering with JohnsByrne – particularly if we get involved early – allows us to call on our deep relationships to bring projects to completion on time and on budget.

8 – STRUCTURAL ENGINEERS ON STAFF

That’s 8 full-time, highly experienced, highly creative structural engineers… the people behind the innovative designs that leverage every possible avenue to the most powerful, brand-centric and cost-effective packaging. Designs that are more sustainable (replacing plastic with paper, for example), more secure like Epik Lok® child resistant packaging), and just plain knock-it-out-of-the-park amazing like Cresco Labs. In concert with our graphic design teams and pressroom gurus, this deep structural engineering capability is a distinct edge for clients demanding breakthrough package design.

0 – ZERO OUTSOURCING

Outsourcing. Ask any manufacturer: outsourcing is the complicating, cascading flaw in most supply chains. So we don’t, mostly. Our domestic, end-to-end solution is uniquely equipped to “make things happen.” Headquartered in the Midwest, independent and privately held for 61 years, with a quality management system 2nd to none, JohnsByrne’s entire operating model is designed around providing innovative solutions and options, with single source accountability right here at home.

As for the issues we do face, JohnsByrne can address them faster and more effectively. because of our strategic and differentiated approach. As a leading domestic manufacturer, vertically integrated, value-driven and forward-thinking, even senior leadership is tasked specifically to help manage supply chain issues. Which is really coming into play these days, because our philosophy has put us in a position to anticipate needs, and help alleviate supply chain problems that are crippling many of our competitors.

1 – COMPLETE VERTICAL INTEGRATION

Single = speedy: when everything’s in 1 place, you don’t have to wait for anything to come from another place. Our entire vertically integrated, domestic business model (developed over 6 decades of private ownership) is predicated on that simple truism.

So the 8 structural engineers are in-house. The comprehensive ink lab is in-house. The Limitless Pressroom is in-house. Finishing and fulfillment technologies and capacities ditto. All in 1 easy-to-reach, secure Midwest location. (Which, please remember, is up and running 24/7.) And all fully integrated with our ISO-certified quality systems. Single source efficiency. End-to-end accountability. And voila: no costly, cumbersome outsourcing issues.

+/- (or </>) – CUSTOMIZATION

Some clients need more. Some need less. JohnsByrne is notable in our ability to customize package orders in appropriate quantities without locking you in to large run/large inventory costs. How? By virtue of our rigorous quality management, customized client onboarding, Limitless Pressroom capabilities and end-to-end integrated operations, JohnsByrne has agility and flexibility built in. We’ve grown up nimble, so you can prosper.

1, 2, 3, 4, 5, 6, 7….. – QUALITY CONTROL

Every step of the way, JohnsByrne clients are in consultation with their project team, and so in control of their projects’ critical path events and ultimate quality. Accessibility is a key benefit of working with an integrated domestic packaging partner. With JohnsByrne, it’s all here for you in the U.S.A.

OTHER VERY IMPORTANT NUMBERS

These are found amid our Forecasting Analytics: a very powerful tool used to analyze previous production data and so uncover new/additional printing efficiencies and inventory management hacks. It’s intrinsic to our ISO quality culture of continuous improvement. Every order is also a teaching moment. And JohnsByrne customers enjoy the benefit.

84 – OUTSTANDING CUSTOMER SATISFACTION

That’s our Net Promoter Score (NPS) in the most recent study of customer satisfaction. And it’s much, much higher than the average NPS score of 25-33 for B2B companies. What that tells you is that real customers have awarded JohnsByrne 4.8+ out of 5 for innovation, structural design, product quality and end-to-end capabilities (among other very positive ratings). And we already mentioned how particular they are.

All of which adds up to the many ways JohnsByrne delivers more quality and innovation, on-time and on-budget, as the integrated domestic packaging partner of choice for leading global brands.

It also adds up to 1 Very Simple Fact: if you can imagine it, JohnsByrne can put it on a press.

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But our current customers say it best. This infographic reveals our most recent customer survey results.

Keep in mind that Net Promoter Score (NPS) is one of the gold standards of customer experience metrics, measuring brand loyalty with a single-question survey: “How likely is it that you would recommend Brand X to a friend or colleague?” on a 1-10 scale.

Promoters (9-10) are loyal enthusiasts and refer others. Detractors (0-6) are unhappy customers who may badmouth your brand. Subtract the % of total Detractor responses from Promoter responses to get the Net Promoter Score. The higher the score, the greater the customer happiness with their brand experience.

Our NPS is 84 (vs. your average B2B score of 25-33.)

The rest of the ratings pretty much speak for themselves.

Most importantly, take a look at our client list for context. These are the responses of senior executives of the companies we serve. Some of the world’s leading enterprises in Finance, Health & Beauty, Entertainment, Food & Beverage, Wine & Spirits and more. Companies renowned for the high standards they set for every vendor partner.

Before your next packaging project, ask yourself one question: “If the most demanding companies in the world prize their partnership with JohnsByrne this highly, why aren’t we talking to JohnsByrne?”

Learn why so many rated JohnsByrne so highly in customer service by scheduling your innovation consult today!

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At JohnsByrne, we continue to press the limits with our innovative technology and creative collaboration between our packaging experts in every department. This results in award-winning packaging that engages and excites.

Overall, JohnsByrne took home 7 awards at this year’s ceremony including a Judges award.

JohnsByrne 2020 PPC Competition Awards

According to the PPC, all entries must be:

• Submitted by a PPC member
• Made in their facility
• Produced and sold between January 1, 2019 and May 1, 2020 for the first time
• Made of at least 50% paperboard that can be seen by the user
• Made to distribute, market and protect a product

From the Judges’ Award to the COVID-19 Community Response Award, below is an overview of the awards JohnsByrne earned at this year’s PPC Competition:

COVID-19 Community Response Award: Face Shield

This year, the PPC had noticed members straying from their usual business model and helping out during the COVID-19 pandemic. As a result, they created a new category award, Community Response. This award recognizes members who have worked to help fight COVID-19.

At the start of the pandemic, JohnsByrne was made aware of the severe shortage of personal protection equipment that left essential workers at risk. Our experts worked to help provide a solution and by designing and manufacturing our own protective face shields for those working on the frontline. Our face shields are reusable and easy to sanitize. This design was the result of the collaboration from our structural design team, who shifted from our usual focus to help the first responders at-risk during this time.

Additional PPC Awards

Other PPC Competition awards we won are:

• Judges’ Award
• Gold Award in Innovation
• Gold Award in Digital Application
• Gold Award
• Excellence Award
• Excellence Award in Digital Application

To learn more about the 2020 PPC Competition awards, be sure to check out PPC’s website.

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At JohnsByrne, we recognize the importance of responsible management for the raw materials of our trade. Without proper stewardship of the forests, sustainability is threatened, putting at risk the many environmental, social and economic benefits that forests provide to humanity and other living things on the planet.

In light of this, JohnsByrne is very proud to have achieved Forest Stewardship Council^® Certification. FSC^®-certified businesses are proven to only use “products come from responsibly managed forests that provide environmental, social, and economic benefits.” We have also attained PEFC’s Chain of Custody Certification and are one of only approximately 20,000 companies worldwide that has fulfilled the rigorous requirements to achieve this certification.

What is PEFC?

PEFC is the Program for the Endorsement of Forest Certification. It represents international standards for companies involved in manufacturing products made from the raw materials of forests. The importance of this certification cannot be overstated; it requires compliance with all of the basic ILO Conventions in forest management established since 2001, including protecting ecologically important forests when harvesting materials.

How does PEFC differ from other forest certification systems?

Two major differences between PEFC and other forest certification systems are:

• It is the largest such certification system in the world.
• It is the only forest certification system entirely not-for-profit.

Aligned to its commitment to maintaining sustainability of the forests is PEFC’s commitment to sustainability of family and community. As such, it is the only global certification system that:

• “Upholds the highest standards without exception,” including requiring compliance with all fundamental ILO Conventions in forest management and setting new benchmarks for social issues, such as recognizing the UN Declaration on Indigenous People’s Rights, protecting workers’ rights and prohibiting the most hazardous chemicals and GMOs.
• Maintains an equally high level of stakeholder engagement for all standards.
• “Builds on intergovernmental agreements and globally recognized processes.”

What is PEFC’s Chain of Custody Certification?

As vital as PEFC’s certification of forests is for ensuring the sustainability of forests through responsible management, this represents only the beginning of a long road from raw materials, through manufacturing, and finally into the hands of consumers.

Chain of custody in a legal context provides documentation as to the exact sequence of all movements and disposition of evidence, so that it can be proven that it was not tampered with. PEFC’s chain of custody is a tracking mechanism that goes through a complete supply chain, from the forest to the final product, and offers qualified proof that any wood in the final product or product line began its life in a certified forest. Each company along the supply chain must have met the requirements and have chain of custody certification for an end product to qualify.

Why is PEFC’s Chain of Custody Certification Important?

More and more, environmental consciousness and responsibility have become highly valued by stakeholders at all levels—both in businesses, and as consumers.

As a PEFC-certified, chain-of-custody company, JohnsByrne has proven its commitment to sustainability and proudly demonstrates this commitment by bearing the PEFC label on all packaging we produce.

This is a visible sign that we are implementing and demonstrating ethical business behavior and it allows consumers to make responsible purchasing decisions, while revealing your company’s commitment to sustainability to consumers who purchase your products.

What Are The Additional Benefits Of Sourcing From A PEFC-Certified Company?

The benefits are numerous and will only become more important, as time goes on. To begin with, your use of certified materials can boost your brand among today’s ever-expanding number of environmentally-conscious consumers.

Additionally, we are already at a place where business is a global affair. In a number of countries, certification is currently being mandated for companies to be eligible for licensing to do business, and the number of countries with this requirement is expected to grow. By working with a certified company, such as JohnsByrne, you open the door to new, larger markets for your products.

To learn more…

Contact us at 847-583-3100 for a consultation on how we can help you develop the innovative packaging that will further your brand image, and we encourage you to find out more about the benefits of chain of custody certification.

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PAPERBOARD PACKAGE OF THE YEAR

This slipcase and popup album cover for indie band The Decemberists is something truly extraordinary to behold – receiving not only the overall “Paperboard Package of the Year” but the “Gold” award also. The whimsical, interactive design was envisioned to appeal the band’s dedicated fanbase. Within the rigid slipcase something interesting, unique, and compelling is revealed – a book that transforms into a geometric pinwheel. Within the pinwheel, fans will discover unique pop-ups, specialty die-cut features, and page-turning features with vinyl pockets, each revealed through the user’s journey –an adventure in aesthetic design, color, form, and texture.

Along with the ability to form and reform the package to find hidden treasures, fans are treated to an autographed booklet and a hidden “Illimat” card for the original card game invented by the Decemberists for their fans. The design brings a ceremonial vibe to the boxset.

Called the “Exploded Edition,” this boxset’s most intriguing and impressive feature is the pop-up pinwheel page-turning factor. The entire concept was planned down to the finest creative detail, and truly explodes with unique features never before seen in a boxed set. The packaging is not only innovative and shockingly interesting to touch and experience, it is durable and capable of withstanding engagement by users, over and over.

A true work of art, it was a collaborative work that included the design agency Smog, band manager, and the band members themselves. To bring even more to the design, hidden surprises continue to engage and surprise as this unique package unfolds in the hands of the user. It’s no surprise that this packaging took home a “Gold” award and received the prestigious overall award for “Paperboard Package of the Year”.

INNOVATION AWARD – GOLD

The innovative team at JohnsByrne is the recipient of the Innovation Award for Green Dot Full Spectrum. The unique structure of the packaging of this cannabis product is certified child-resistant, a critical feature for all cannabis products. Green Dot decided to partner with JohnsByrne and incorporate their state-of-the-art CR packaging solution, EPIK LOK. EPIK LOK uses the highest Compliance Standards and Green Dot recognized this packaging as the safest most secure option for their Green Dot Full Spectrum product. To open the packaging requires pressing down on two pressure-release tabs, and then sliding an addition tab into a slot.

Beyond the high level security this packaging offers consumers, the package has a uniquely luxe quality that draws the eye, the hand, and the consumer.

The JohnsByrne team faced some challenges in developing the EPIK LOK packaging, as it came with two problems: the locking mechanism must not be able to be operated by any child, but must be easy to use for adults, including seniors. The packaging must be single assembly, and provide full bite, chew, and saliva resistance. Normal packaging concepts were out the window, as glue flaps, edges, corners and exposed trays all pose a risk of access by children.

The JohnsByrne team took these challenges in stride and were able to produce a remarkable packaging innovation with a structure and locking mechanism that will prove to be useful for a range of pharmaceutical products in various sizes and shapes.

JohnsByrne is engaged in created innovative designs for a range of industries and doesn’t buy into the status quo. Rather than taking the approach that it cannot be done the design team assumes it can be done – and works out a way to accomplish what seemed impossible. It is of interest to note that in many cases, a better design proves to be more affordable. Don’t assume that the wheel can’t be reinvented. At JohnsByrne, that’s our approach, from initial concept, to design, to the most advanced printing methods with the goal of achieving maximum consumer appeal.

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The competition is the premier competition for packaging manufacturers, with categories that include everything from concept and design to performance and shelf appeal of the carton. JohnsByrne is thankful to work with great customers looking to press the limits on packaging. Turning your ideas into award-winning packaging is at the core of what we do. At JohnsByrne, each packaging or print project is unique and presents an opportunity to innovate and press the limits on what’s possible, resulting in one-of-a-kind print and packaging pieces that are not only standouts in their category, but also drive sales and results.

This year, JohnsByrne has been awarded 6 PPC awards for 2017, including:

1. Judges’ Award – Ryan Adams Prisoner: End of World Box Set

A recipient of a prestigious Judges’ award, this vinyl box set for Ryan Adams’s 17th studio album is a collector’s classic! The multi-component box is visually intriguing and fully interactive. Ryan Adams fans are delighted to open a three-dimensional stage, complete with sound and light features and even paper cutouts of Adams and his bandmates.

Navigating the complexity of multiple rigid wrap components, running wires, as well as a battery component, we were still able to include features like a trapdoor that reveals a secret vinyl. Invisible ink, which becomes visible when exposed to blue light, displays a secret website where fans can find additional content.

2. Gold and Innovation Award – Courvoiser

This design is the third generation of the cartons we’ve developed for Courvoisier to commemorate Chinese New Year. The design has evolved from a basic SBS carton to a rigid set-up box with foil stock, and this year we wanted to do something truly special.

To give the rooster an unforgettable look, we used a unique thermo stock that is designed to react to heat. We used a foil stamping dye (with no foil ribbon being used) to cause a reaction that changes the color of the stock. Hence the dark, burnished look achieved for the rooster image.

3. Gold Award – Sublime Limited Edition Vinyl Box Set

This stunning superset is every Sublime fans’ dream. The package contains seven albums, a turntable felt pad, and a set of two lithographs printed on 100 pound accent opaque cover in a vellum envelope.

The client wanted the box set to resemble a beat-up Econo van. A variety of materials were required to achieve that vision. For the van shadow box, we wrapped chipboard with 4/C printed matte film lamination. The lid is die-cut, with polyester film for the window so fans can see the Sublime band members inside the van. Other subtle details – the reversed title as if you’re reading it in a rear-view mirror, a marijuana joint, and pine-scented air freshener – bring the vision to life.

4. Gold and Innovation Award –  The Godfather Collector’s Edition

A must for every film buff, the packaging for this trilogy reflects the moods of the films themselves.

The Godfather films are classy, elegant, and timeless. To achieve this look, we applied an overall 4/C process to silver mylar foil board, then used a custom white plate to coat the print. Soft touch coating made for the perfect finishing touch, giving the package a rich, velvet-like texture. A screen of white and gold tinted title treatment pull it all together.

5. Gold Award – Thymes Collection

Thymes needed packaging for their line of soaps, scents, and diffusers. Their challenge was to maintain brand identity and continuity while keeping within their desired price point.

The line included nine scents. Because each scent had its own color scheme, light, medium, and dark woodgrain patterns to complement the full spectrum of colors used.

The end product has a high-end look and feel, yet is still cost-effective. This was possible thanks to our unique press capabilities, which allow us to combine multiple textures and finishes. Our Press384 helped us to hit the light pastels (difficult color targets) while maintaining impeccable quality.

6. Excellence Award – Nerium Gift Kit

Nerium doesn’t sell their skincare and wellness products in stores, opting instead to sell direct in consumers’ homes through sales consultants. So their holiday gift sets needed an attractive package.

This is the second year we are producing the holiday packaging. This year we coated the sleeves in PMS blue, with a soft touch coating and spot gloss UV to accentuate the embossed “bubble” design on the front of the package. A picture frame style tray was designed to house multiple Nerium product boxes.  Also, the tray was designed with 2-piece and 3-piece interchangeable inserts that allowed Nerium to use the same packaging for both gift set options.

Want to see more packaging? Check out our work gallery!

You can also view past PPC award winning packaging from 2015 and 2016.

The post JohnsByrne Wins 6 Paperboard Packaging Council Awards appeared first on JohnsByrne.

Every year, the Paperboard Packaging Council (PPC), issues awards to the “best of the best” produced by the packaging industry. JohnsByrne

Judge’s Award – Casamigos Tequila Folding Carton

Presenting a new high-end tequila on the market – even if you are George Clooney and his partner – demands outstanding packaging that communicates quality, desirability, and attracts the eye of a tequila buyer. The Casamigos tequila folding cartons were produced on a one-of-a-kind press, Press384 that has three coating units and eight print units that were used to apply soft touch, gloss UV, dull varnish and PMS colors. The folding cartons also featured pre and post foil stamping to spotlight the signature agave leaves. The design was completed with artful embossing that rendered a realistic, aged, wood-grain look and a textural appeal that stimulated all the senses.

Gold and Excellence Award – Image Skincare – YANA Folding Carton

The YANA line was a new product launch for Image Skincare. This award-winning design was crafted to have an overall rich, luxurious look and feel, with a very signature pearl effect. To achieve the pearl look in the most cost-effective way, the JohnsByrne team employed their one-of-a-kind press, Press384 that has an upfront coater unit where the pearl coating was applied. Having this technology and option eliminated the need for more costly options such as special ‘pre-pearlized’ sheets. The resulting carton has the appearance of the most luxurious, high-end brands, with a subtle pearlized finish, silver foil stamping, and perfectly registered logo embossing.

Gold Award – Basil Hayden Limited Edition Rigid Box

The Basil Hayden Limited Edition rigid set box was produced for Beam Suntory. This promotional VAP was released for the holidays and contained the premium Basil Hayden bourbon bottle along with a copper shaker that together creates the perfect imagery of a great night with friends. The copper shaker was chosen to match the copper band on the bottle’s labeling and the Basil Hayden logo (on box) was foil stamped with that exact copper color to provide perfect brand continuity.   The realistic and savvy linen pattern on the box was executed on-press through reticulation which alleviated the need for consideration of an expensive stock paper wrap.

Excellence Award – Knob Creek Limited Edition Rigid Box

The JohnsByrne team was invited for a second year to develop and produce a rigid package for the premium Knob Creek brand. The two-piece telescoping VAP with window design needed to accommodate both the bottle and two limited edition old-fashioned rocks glasses. The package presented the classic look of the old west and featured a clever‘ drop card’ (inside the box) printed with an antique newspaper pattern that resembles the Knob Creek label. . The special challenge of this project was to precisely register the wood grain embossing around the Knob Creek logo and type copy. The final product was perfectly executed, had a rustic appeal, and was covered in subtle embossing for a pleasurable tactile experience geared to entice and engage customers.

Excellence Award – 2015 Holiday Gift Box

Every year, the JohnsByrne team celebrates the holiday season by developing an innovative and memorable gift box that is given to clients, partners and friends. This annual gift box project capture the year’s newly discovered innovations in technology, structure and finishing’s and allows us to press the limits. The gift box was designed with three coatings; pearl, UV gloss and soft touch that were printed in a single-pass on our triple coater press, Press384. Through the single-pass process, the upfront pearl with UV gloss over top resulted in a reticulation reaction that produced a new ‘raised glitter’ effect that eliminated the need for a planned glitter coating. Rich blacks and reds on mylar captured the holiday mood and season.

Want to see more packaging? Check out our work gallery!

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