Product Packaging

We have a great working relationship with the guys at Evans Cycles so we were only too happy help them in printing a few prototype sheets for a new range of product packaging.  Initial test sheets did not go as well as planned as we were trying to simulate a silver foil finish with a digital enhancing press using a polymer gel which struggled to cope with fine detail.  Not to be beaten by the short comings of technology we had an internal discussion and reviewed materials and processes to come up with a solution which the customer could take forward.  As this was for their new, high end range of tools and accessories it was crucial that we got it right for them.

After a few days the prototype sheets were ready, the new materials and process paid off and they looked amazing. Instead of using a white sheet and foiling, we used a silver mirror finish board, white ink and reversed out black type which achieved the desired effect leaving crisp text and sharp images gleaming through in metallic silver. Finally, we used the enhancing press to simulate the spot UV varnish that would be applied on the full run.

It’s funny how one thing can often lead to another…

On seeing the prototype sheets, Evans Cycles’ head designer was delighted with the results. So much so it prompted further discussion and details for the full production run.

The prototypes were approved and we were asked to quote for the full production run.

The design for the range and packaging was great and it was up to us to turn it in to a physical product that echoed the same level of quality as the accessories themselves.  It’s clear that we share a common value with Evans Cycles of “Quality Makes It Better”.  The pumps are made of aluminium and are quite heavy, not in terms of bike pumps, but in terms of hanging from a piece of card. We had to make header boards strong enough to hold up on an in store hanger .  We devised a method of triplexing 3 sheets together; the top sheet being silver mirror board (the customer facing side), the middle section a 1250 micron board to add rigidity and strength and the back sheet containing product information, barcodes etc.. a white uncoated sheet.  Once bonded together the outcome is a super thick header card!

Product embellishment:

The spec for this was straight from the design team and needed no intervention from us – it suited it perfectly; an overall matt laminate to contrast the gloss spot UV, once die cut to shape and pushed out the sheet the product came to life.


As we share the same trading estate we thought we could add further value to the project by offering our fulfilment service. This minimised physical movement of the products (all 15 pallets worth) which saved a huge amount in transport costs, drastically reducing the time to market and enabling Evans to distribute to their 60 stores quickly.

The initial batch of 200 items of 8 different products was delivered within a few days of the printed sheets being die cut. From then we set up a regular delivery every week to further supply the provisions warehouse.  After some 15,000 items delivered, the first batch of this product line is completed.  Roll on the next batch!

A few words from the client:

“Burst have always produced a first class experience no matter what the job, but when we approached them for a new packaging project they certainly pulled the stops out. With the nature of the brief they sat down with us on numerous occasions throughout the process to discuss all the best practices and techniques along with what materials would work best to achieve the look we were after. Burst not only handled print but took on all the fulfilment too. The result was a premium finish to compliment the product and a job I am particularly proud of”

Spencer Carter – Head Designer

Check out the Evans Cycles website here for a great deal on a new bike! And the Flynt range can be found here The Flynt range

If you have a project in mind that you would like to explore or need a clever solution to a print orientated product please feel free to get in touch on 01293 660723.


Flynt Multi Tool Header Card Bike pump header card

Packaging Innovations: The Future is Digital

The potential of digital print is constantly broadening, and its benefits for packaging are only just being realised. In terms of customer engagement, personalisation, and re-usability, digital print has opened up a whole new world of opportunity. As the print quality has improved, the advantages of digital print have become clearer. In 2016, we will see more digitally printed packaging on retail shelves than ever before.

With millennials now considered the most influential generations, the behaviour of brands is changing. Packaging is consistently identified as one of the major influences on everyday purchase decisions and with generations engrossed with anything visual, packaging design characteristically outweighs the practical attributes of a product.

The challenge that is faced by brand owners now is how to leverage digital print to drive profit from innovative marketing campaigns. With customers desire to connect with brands on all levels, brands have to work harder to get their market share by offering consumers a truly special experience with their product.

Personalised Packaging

Personalisation is the latest buzzword and has become a novel way to reach out to the masses. We have seen this from big brands such as Coca-Cola, Nutella and Marmite who have utilised digital print technology to personalise their bottles and jars.

In 2013, Coca-Cola started their infamous ‘Share-A-Coke’ campaign. The campaign saw them print 100,000 of the most popular names on the Coke bottle labels all over the world. This delivered a 6.8% increase in their global Facebook community and their values sales have increased 4.93% year on year since the campaign started.

Personalised packaging has proven popular amongst brand owners. It can give brands more direct contact with customers and strengthens the relationship that they are trying to build. Digital print has enable personalisation on a scale that wouldn’t be possible using the more traditional printing methods.

Interactive Packaging

Packaging has always been interactive. The look, the colour and the shape are just a few elements that subconsciously impact our perception of a brand. As mentioned, the design of the packaging for many is more important than the actual product attributes itself. With this in mind, digital print has allowed brands to explore interactivity with use of electroluminescent inks and conductive inks.

Packaging Oculto Light Up Beer BottleOculto, a lager blended with beer aged on tequila barrel staves recently unveiled two new interactive packaging innovations. These included a first-of-its kind illuminated bottle design that featured smart label technology. The smart label was created using electronic pathways, paper batteries and LED lights that were activated with a pressure switch. The switch was placed where the thumb naturally falls while holding a beer bottle, and once pressed; the LED light began to shine. This technology was a clear demonstration of how packaging and marketing can give customers a full sensory experience.

Brand owners aren’t just concerned with marketing gimmicks though; they are much more concerned with the practicalities interactive packaging can offer. Packaging for prescriptions could soon connect to your phone to give you a reminder when you need to take your next dose. Researchers are also working on an early-warning system that enables packaging to sense changes in the condition of the packaged food. Smart labelling and colour changes would be used to transmit those changes informing the consumer their products are no longer fresh. This development in intelligent packaging could dramatically reduce food waste.

Multi-Use Packaging

Packaging McDonlad's VR Headset

As a nation we have become more conscientious about our waste and the UK now has the fastest growing rates of recycling in the UK. With that in mind, brands are working to transform packaging from otherwise useless receptacles into useful items. Last year saw Ogilvy and Mather Tokyo turn Pizza Hut’s cardboard box into a working film projector. Powered by the user’s smartphone, the box contained a small lens which was inserted into a perforated hole in the side. When the user’s smartphone was placed in the box, the screen was displayed onto the wall.

Brands are also striving to make new technology accessible to all through their packaging. When Google released Cardboard, its paper-and-velcro VR headset, the guys over at McDonald’s Sweden noticed an opportunity. In March of this year, McDonald’s began selling a limited number of Happy Meals in special boxes. With a little construction, these could be transformed into VR headsets. By tearing eyes and nose holes and inserting lenses, kids got free a VR headset. Customers who bought one were then also given an access link to download the Happy Goggles VR game, an animated skiing-race game called ‘Watch Out on the Slopes’. Investing in this new and exciting technology has proven a smart way at making consumers feel involved with a brand.

Retail continues to change at a dramatic pace and the demand for personalised and engaging experiences call for new approaches to packaging. With end users making the move to digital, print is now the major player in bridging the gap between physical products and the digital world.

Written by Liam Beauchamp for Burst Digital – 27/06/2016

Burst Digital

We are constantly pushing the boundaries with print. We also house some of the latest digital print technology that will allow you to produce dynamic and personalised marketing print assets that will open up channels to your customers and products.