Designing and Fine-Tuning Packaging for Castrads’ Hornbeam Cast-Iron Skillets

Objective

Hornbeam Cookware was preparing to launch their new high-end British-made cast iron skillets.

Sister brand to Castrads, a renowned name in premium cast iron radiators, with Hornbeam the team wanted to make a strong impression as they moved into a new market segment.

They approached us with the challenge of designing packaging that would not only securely house their heavy pans but also provide an exceptional unboxing experience that reflected their brand’s reputation for quality.

This case study details our collaborative process with Hornbeam Castrads, conducted via email and video calls, as we worked together to develop, test, and refine the perfect packaging solution that balanced product protection with aesthetic appeal.

Client	Hornbeam Cookware
Industry	Cookware
Project	Custom Retail Printed Boxes with Inserts

Project Challenges

Castrads’ new cast iron pans posed unique packaging challenges due to their significant weight and the delicate nature of the polished and pre-seasoned enamel finish.

They also needed us to accommodate two size options as they produce both 10 inch and 12-inch diameter pans. The packaging needed to:

Support the heavy weight of the pans during transit while protecting them from movement and potential damage.
Safeguard the finish and design of the pans, ensuring no scuffs or marks on the hand-finished their high-end surface.
Offer an elegant unboxing experience, with subtle reveals of the product while maintaining the robust protective elements.
Incorporate Hornbeam’s Castrads’ branding and design elements through custom print and artwork, creating a cohesive brand experience for customers.

Given these requirements, we knew that a standard packaging approach wouldn’t suffice. The packaging had to be custom engineered to manage the weight while still allowing for the refined presentation Hornbeam Castrads envisioned.

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The Design Process

Our design team worked hand-in-hand with Hornbeam Castrads from concept to execution. Here’s how we approached the challenge:

1. Initial Discussions and Concept Development

Through a series of detailed email exchanges and video calls, we collaborated closely with the team from Hornbeam Castrads to fully understand their expectations.

Their priority was twofold: to create packaging that could withstand the rigours of shipping such a heavy item, and to deliver an unboxing experience that reflected the premium quality of their brand.

We explored initial ideas for multi-layered packaging structures that would distribute the weight of the pans evenly, while still providing the opportunity to reveal elements of the pan in a visually engaging way.

2. Prototyping and Weight Management Solutions

Our first step was to tackle the structural integrity of the packaging. We designed prototypes using double-wall corrugated cardboard, chosen for its superior strength and ability to support the pans without adding unnecessary bulk.

The internal packaging consisted of custom die-cut inserts, engineered to cradle the cast iron pans securely.

Each insert was meticulously measured to account for the unique dimensions of the pans, including handles and other features.

These inserts were not just there to hold the product in place, but also to ensure that no part of the pan’s surface would come into contact with the outer packaging—preventing any risk of damage.

3. Testing and Refinement

Given the weight of the cast iron pans, we conducted a series of rigorous stress tests to ensure that the packaging could endure the demands of shipping.

These tests simulated real-world conditions, including drop tests, vibration resistance, and compression underweight.

After several rounds of testing, we adjusted the design, increasing the thickness of certain materials where necessary and reinforcing critical points of stress.

The goal was to provide maximum protection without sacrificing the aesthetic or functionality of the packaging.

4. Creating the “Wow” Factor with Subtle Reveals

While the primary focus was on protection, Hornbeam Castrads was equally concerned with the customer experience upon unboxing. They wanted their customers to feel the premium nature of the product from the moment they interacted with the packaging.

Instead of opting for magnetic flaps or other complex opening mechanisms, we collaborated on a more subtle solution.

We integrated small cut-outs into the outer packaging that revealed select details of the pan—such as the pan size or the cast iron surface—without compromising the structural integrity of the insert holding the product in place.

These cut-outs created a sense of intrigue, allowing the customer to catch a glimpse of the pan before fully opening the box, heightening the anticipation.

Additionally, the interior layout was designed so that once the customer lifted the lid, the cast iron pan was presented in a precise, elevated position, cradled securely by the custom die-cut insert. This added an element of sophistication to the unboxing process, mirroring the craftsmanship of the product itself.

Artwork and Print Collaboration

Once the structural design was finalised, we shifted our focus to the artwork and branding. Hornbeam Castrads had a clear vision for the packaging’s exterior, wanting it to communicate the premium quality of the pans while

establishing their new and unique staying true to their brand identity.

1. Custom Branding and Finishing

We worked closely with Hornbeam’s Castrads’ marketing team to ensure the packaging echoed their distinct branding. After reviewing colour palettes and logo placement, we created several iterations of the design to make sure the final product would stand out, both online and in-store.

We employed high-quality Flexo printing to achieve vibrant and consistent colours, paired with a white ink underpinning to brighten artwork on brown board and exude luxury.

2. Artwork Alignment

The cut-outs required precise alignment with the artwork so that the glimpses of the pan were intentional and engaging. This meant a lot of back-and-forth revisions to ensure everything lined up perfectly, balancing function with aesthetics.

We worked diligently with Hornbeam Castrads to ensure that every detail of the packaging was not only visually striking but also technically sound.

When underpinning with white ink it is important to ensure alignment with registration between colours and stereos and this is something we pride ourselves on ensuring during the set-up, print and quality control process to get spot on.

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Final Approval and Production

Once the structural integrity and design aesthetics were perfected, Hornbeam Castrads approved the final prototype, and we moved into full-scale production.

The packaging solution we developed met all of Hornbeam’s Castrads’ goals: robust protection for their heavy cast iron pans, subtle yet impactful reveals for an elevated unboxing experience, and branding that reflected the premium nature of their new product line.

Conclusion

This project with Hornbeam Castrads exemplified how a collaborative approach between client and supplier can result in a packaging solution that goes beyond just function.

Together, we developed a packaging design that balanced heavy-duty protection with elegant presentation, giving Hornbeam Castrads the confidence that their cast iron pans would arrive in perfect condition while offering their customers an exciting unboxing experience.

The successful product launch will be a testament to the attention to detail, precision, and teamwork that went into every stage of the design process, and we continue to support Hornbeam Castrads with their packaging needs as their product line evolves.

Last Modified:

November 28, 2024