Murray Sons and Co., Ltd. and G2 Worldwide were looking for a turnkey solution when choosing a packaging supplier for their holiday promotion for Dunhill Cigars, an internationally renowned premium cigar made in the Dominican Republic. They turned to Diamond Packaging to manufacture the cartons and provide fulfillment for this elaborate marketing campaign.

The entire Dunhill line consists of six different types of cigars (Churchill, Toro, Torpedo, Corona, Robusto, and Petit Corona), each packaged three per carton. Although all six cartons shared similar graphics, each cigar type specified different sizes for each of the components within. Furthermore, the upscale packaging needed to reflect the quality of the product within.

Diamond delivered by producing all of the packaging components and providing fulfillment services for the project. Our ability to do so within a narrow timeframe allowed Murray Sons & Co., Ltd. to meet their marketing objectives for this significant promotion.

The outer sleeve was produced on an imported Colorplan paperboard, chosen for its beautiful finish as well as its excellent folding and scoring characteristics. The glued sleeve was designed with both open and sealed ends, which allowed the attractive outer tray to partially extrude, thereby enhancing shelf appeal and maximizing the Dunhill brand identity. The outer sleeve also featured a multitude of graphic enhancements such as multi-color printing (including metallic), UV satin coating, embossing, debossing, and hot foil stamping. The subtle embossing pattern on the front and the back of the carton created visual interest and imparted an unusual tactile effect.

The outer tray and cigar tubes also featured metallic inks and embossing, but were converted from a .014 SBS paperboard. The cigar tubes and inner cell were designed to open and close in a telescoping fashion.

After converting, all of the components were sent to Diamond Contract Manufacturing (DCM) for fulfillment. DCM took control of the entire production flow, including setting up the outer simplex tray; inserting the inner tray; inserting the vellum paper; inserting the inner cell into the tubes; assembling the tube components; packing three tubes per carton; wrapping the vellum around the tubes; inserting the outer tray into the outer sleeve; bulk packing the cartons into cases; and shipping cases to the Dominican Republic. After an initial quantity of 6,000 cartons was produced and ship tested, DCM produced the remainder of the order. Adhering to the narrow timeline of the project, DCM produced a total of nearly 55,000 cartons in just 5 days.

Our ability to step in and manage the project was the perfect fit for Murray Sons & Co., Ltd and G2 Worldwide. The end result is a sophisticated package that truly stands out in the crowded retail environment.