Leading carton manufacturer Falconer Print & Packaging has developed a premium cartonboard pack for independent whisky bottler One Cask at a Time, combining luxury presentation, production efficiency and sustainability for the Scotch whisky market.
Designed for One Cask at a Time’s generic carton format, the pack was created to deliver the shelf presence and tactile appeal typically associated with rigid presentation boxes, while retaining the commercial and environmental benefits of cartonboard.
The innovative eight-panel structure provides exceptional rigidity and a high-end feel, supported by an oversized format that enhances stand-out in premium retail environments. A recessed central panel allows variable labels to be applied across different whisky expressions and age statements, enabling production flexibility and economies of scale.
Produced using FSC-certified virgin fibre cartonboard from Holmen, the fully recyclable pack offers a responsible alternative to heavier rigid formats and removes the need for plastic vac-formed inserts. Its one-piece, flat-packed construction also improves pallet efficiency, reduces transport volume and supports faster assembly on the bottling line.
Visually, the carton delivers a highly sensory consumer experience through metallic inks, intricate hot-foil detailing, embossing, debossing and contrasting gloss finishes. The result is a pack that communicates craftsmanship, exclusivity and quality while encouraging consumer interaction. Falconer’s CAD team developed the structural design, with graphic design by Bombcrater.
Russell Bradley, head of brand development at One Cask at a Time, said: “Falconer has been an absolute delight to work with throughout this project. From the earliest stages of development, the team demonstrated exceptional expertise, creativity and attention to detail, delivering a finished pack that exceeded our expectations. The whole team have been professional, responsive and a genuine pleasure to work with and we are already exploring future collaborations together.”
Colin Pow, sales and marketing director at Falconer, added: “This project perfectly demonstrates how cartonboard can deliver the premium appearance and tactile quality expected within the luxury spirits sector, while also offering strong sustainability and operational benefits. By combining innovative structural design with high-end print finishes, we were able to create a pack that delivers real shelf impact without compromising recyclability or production efficiency.”
Falconer specialises in manufacturing decorative printed folding cartons for several industries, including pharmaceuticals, cosmetics, beverages, spirits, giftware, healthcare, veterinary, pet care, and luxury confectionery. The company is known for incorporating high-quality added-value finishes and state-of-the-art equipment, enabling it to deliver innovative packaging solutions and exceptional customer service.
For more information about Falconer and its comprehensive packaging solutions, visit www.falconerprint.co.uk.