The Challenge

As a leading luxury packaging partner for DTC brands, Haus of Brilliance required a high end, functional packaging design solution that would not only reflect the premium nature of its products but also withstand the rigors of international shipping.

An early shipment revealed a critical issue: while their custom packaging boxes, made from unlaminated paper, performed well in India’s dry environment, they failed in high-humidity destinations. The moisture caused the boxes to swell and seal too tightly, making them difficult to open. This compromised both usability and the luxurious unboxing experience the brand was known for, leading to operational delays and negative customer feedback.
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What We Did

01 Root Cause Analysis
02 Material Upgrade Laminated Eco Friendly Paper
03 Structural Redesign Vacuum Free Sleeve Format
04 Moisture Control Silica Gel in Master Cartons

Phase 1: Root Cause Analysis

Phase 1
Our packaging engineers conducted an in-depth assessment of transit conditions. The issue was linked to moisture absorption during ocean shipping and warehousing. The tight, closed structure of the box exacerbated the problem, causing a vacuum effect that trapped humidity.
Outcome: Environmental durability was made a core priority in our custom packaging solutions moving forward.

Phase 2: Material Upgrade Laminated Eco-Friendly Paper

Phase 2
To combat the moisture issue, we transitioned to laminated art paper with a soft matte finish providing a balance between performance and luxury.
  • Laminated surface acted as a moisture barrier
  • Paper remained eco friendly, aligning with sustainability goals
  • Finish and form were tested under both humid and dry climates
  • Tactile appeal and brand aesthetics were preserved
Outcome: The new sustainable packaging maintained structural integrity across climate zones, with zero swelling or deformation.

Phase 3: Structural Redesign Vacuum Free Sleeve Format

Phase 3
Next, we reimagined the packaging structure for improved airflow and ease of use:
  • Replaced the closed-fit box with an open sleeve format
  • Introduced internal ventilation paths to prevent condensation
  • Retained the premium brand presentation and innovative packaging design
Outcome: Packaging was easier to open, with no resistance even in high humidity destinations.

Phase 4: Moisture Control Silica Gel in Master Cartons

Phase 4
As an added safeguard, we introduced silica gel pouches during the shipping process:
  • Integrated into every master carton
  • Controlled humidity during long-haul transit and storage
  • Protected both the luxury packaging and product contents
Outcome: Improved moisture resistance and consistent quality upon delivery.

Final Highlights

  • Custom packaging solutions optimized for eCommerce brands and global distribution
  • Eco friendly packaging materials that balance performance with brand values
  • Structural redesigns eliminated the vacuum effect and boosted usability
  • SOPs for moisture control ensured long-term packaging performance
  • Resulted in fast packaging manufacturing turnarounds and error-free reorders

Outcome of Our
Production Journey

This success story underscores the importance of sustainable packaging solutions tailored for international markets. With a mix of tech enabled packaging, climate specific materials, and user friendly structures, Haus of Brilliance overcame a critical shipping challenge.
Today, the brand continues to scale confidently, backed by a reliable packaging company that delivers modern packaging solutions in India and beyond.
If you're an eCommerce or luxury goods brand seeking a trusted packaging partner for DTC brands, reach out to us for custom packaging that performsno matter the destination.