At BP Solutions Group, with our century of manufacturing expertise, we've witnessed firsthand how crucial custom folding cartons have become in the beverage industry. From craft breweries and wineries to specialty sodas and functional beverages, the right packaging solution can elevate your product from ordinary to extraordinary.
The Evolution of Beverage Packaging
Beverage packaging has transformed dramatically over the decades. What once served merely as functional containers has evolved into sophisticated marketing tools that communicate brand values, product quality, and connect emotionally with consumers.
The craft beverage revolution has particularly accelerated this evolution. As consumers increasingly seek unique, premium experiences, packaging has become an extension of the product itself. Today's beverage cartons don't just hold products—they tell stories, create experiences, and distinguish brands in meaningful ways.
Key Shifts in Beverage Packaging:
- From generic to highly customized packaging solutions
- Increased focus on shelf appeal and visual differentiation
- Greater emphasis on sustainability and eco-friendly materials
- Integration of packaging into broader brand storytelling
- Enhanced functionality for specific consumer needs (portability, protection, convenience)
The Design Process: Creating Custom Beverage Cartons
Creating effective beverage packaging begins long before production. The design process involves multiple stakeholders and considerations to ensure the final product meets both aesthetic and functional requirements.
Discovery Phase
The journey begins with understanding your brand, product, and market position. We assess:
- Brand identity and values
- Target audience preferences
- Competitive landscape analysis
- Retail environment considerations
- Distribution and handling requirements
During this phase, our team works closely with yours to define objectives, constraints, and opportunities that will guide the design process.
Conceptualization and Design
With a clear understanding of your needs, our designers develop concepts that balance aesthetics, functionality, and brand alignment. This process includes:
- Structural design of the carton
- Graphic design elements
- Color selection and application
- Typography and messaging
- Special finishing considerations
Multiple concepts may be developed and refined based on feedback, ensuring the final design perfectly captures your vision while meeting practical requirements.
Material Considerations for Beverage Packaging
Selecting the right board stock is crucial for beverage packaging success. Different beverages have unique requirements based on weight, moisture resistance, temperature conditions, and shelf life.
Common Board Stock Options:
- SBS (Solid Bleached Sulfate): Premium white board with excellent printing surface, ideal for high-end beverage packaging requiring vibrant graphics
- SUS (Solid Unbleached Sulfate): Natural kraft appearance with strong environmental messaging, popular with craft beverage brands
- Recycled Board: Environmentally friendly option with varying percentages of post-consumer waste
- Specialty Boards: Including metallized, textured, or uniquely coated stocks for distinctive packaging
When working with a client like Darë Vegan Cheese, material selection was crucial. Their previous packaging was plastic wrap with a label, but transitioning to a carton significantly increased their shelf visibility while elevating their branding.
Performance Considerations:
- Moisture resistance for refrigerated products
- Structural integrity for heavier products
- Compatibility with desired finishing techniques
- Sustainability credentials and recyclability
Printing Techniques for Beverage Packaging
The printing method chosen can significantly impact the final look and feel of beverage packaging. At BP Solutions Group, we offer various printing techniques to achieve your desired results.
Offset Printing
Traditional offset printing delivers exceptional color accuracy and detail, making it ideal for premium beverage packaging with complex designs or brand-critical color matching.
Digital Printing
Digital printing offers flexibility for smaller runs and variable data printing, perfect for craft beverages with seasonal variations or limited editions that require quick turnarounds without sacrificing quality.
Color Considerations
Beverage packaging often requires precise color reproduction to maintain brand consistency. Our color management systems ensure your brand colors appear exactly as intended across all packaging elements.
When Hi-Wire Brewing approached us for their keg collars, color consistency was paramount. These collars identify the type of beer in each keg and are vital for their distribution to restaurants and vendors, requiring perfect color reproduction to maintain brand recognition.
Specialty Finishes for Beverage Cartons
Finishing techniques can transform ordinary packaging into extraordinary brand experiences. These special effects create visual and tactile elements that enhance consumer perception of quality and value.
Popular Finishing Techniques:
- Spot UV Coating: Creates contrast between matte and glossy areas
- Embossing/Debossing: Adds tactile dimension and premium feel
- Foil Stamping: Metallic accents that catch light and attention
- Soft Touch Coating: Velvety texture that invites handling
- Window Patching: Allows product visibility while maintaining structural integrity
When working with Carolina Day School on their viewbook, we implemented a soft touch aqueous coating overlaid with spot UV to achieve the desired effect on their bell logo image. Similar techniques can dramatically enhance beverage packaging.
Structural Considerations: Functionality Meets Design
Beyond aesthetics, beverage packaging must perform specific functions—protecting products, facilitating distribution, enhancing user experience, and supporting retail display.
Key Structural Elements:
- Strength and Durability: Ensuring cartons withstand handling throughout the supply chain
- Opening and Closing Mechanisms: Creating intuitive, satisfying user interactions
- Multi-Pack Solutions: Designing carriers that balance economy with presentation
- Retail Display Functionality: Incorporating features that enhance shelf presence and merchandising opportunities
For Hemptron's CBD pouches, we developed a point-of-purchase display carton specifically designed to hold their pouches upright while easily converting into a shelf display piece, demonstrating how structural design can enhance retail presentation.
Sustainability in Beverage Packaging
Today's consumers increasingly demand environmentally responsible packaging. The beverage industry has responded with innovative approaches to sustainability without sacrificing quality or performance.
Sustainable Approaches:
- Material Reduction: Designing packaging with optimal material usage
- Renewable Resources: Using papers from sustainably managed forests
- Recyclable Solutions: Creating packaging that integrates seamlessly into existing recycling streams
- Biodegradable Coatings: Replacing traditional plastic coatings with eco-friendly alternatives
- Energy-Efficient Production: Leveraging manufacturing processes that minimize environmental impact
Our commitment to sustainability is reflected in our Forest Stewardship Council® certification (FSC-C103525), allowing us to provide many options for FSC® certified paper. This means your beverage packaging can have a positive environmental impact while maintaining extremely high quality.
FAQ: Custom Beverage Packaging
What minimum quantities do you require for custom beverage cartons?
Our digital production capabilities allow us to accommodate both small-batch craft beverage producers and large national brands. We offer solutions starting from lower volumes with no plate charges, making custom packaging accessible regardless of your production scale.
How long does the custom beverage packaging process take?
Timeline varies based on complexity, but typically ranges from 2-6 weeks from concept approval to delivery. We work closely with clients to align with product launch schedules and can accommodate expedited timelines when necessary.
What information do I need to provide to start a beverage packaging project?
Basic requirements include product dimensions, quantity needed, design preferences (if available), timeline, and any specific functional requirements. Our team can guide you through gathering all necessary specifications.
How can beverage packaging improve my product's shelf appeal?
Custom cartons create immediate visual differentiation, communicate quality through materials and finishes, and allow for creative brand storytelling that connects with consumers emotionally—all crucial factors in driving purchase decisions.
Is sustainable beverage packaging more expensive?
While some sustainable materials may have higher initial costs, the total impact on packaging budget is often minimal. Additionally, consumers increasingly value and will pay premium prices for environmentally responsible packaging, potentially offsetting any cost difference.
Partner with BP Solutions Group for Your Beverage Packaging Needs
For 100 years, BP Solutions Group has been helping beverage brands create packaging that performs in the marketplace. Our combination of technical expertise, creative capabilities, and manufacturing excellence makes us the ideal partner for beverage companies seeking to elevate their packaging.
Whether you're launching a new product, refreshing an existing line, or seeking more sustainable options, our team is ready to guide you through every step of the process—from concept to shelf.
Contact BP Solutions Group today to discuss how we can transform your beverage packaging into a powerful brand asset.
