Behind the Box... Creating Custom Packaging for Unfold
11 Nov


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One of the best parts of our job is helping a new brand bring their ideas to life.
Businesses often come to us with a vision and a box of products and after a few chats and sample runs, we build packaging that keeps everything safe and feels true to them.
Recently, we teamed up with Unfold, a West Yorkshire-based wellbeing brand, to design and make a custom foam insert for their flagship gift box, 'Night Reset'.
Founders Rachael Smith and Michelle Kynaston started Unfold with a simple question: "How often do we truly stop?" Instead of just another wellness hamper, they wanted to create a guided evening ritual. Night Reset is all about helping people switch off from a busy day and properly unwind.
The Packaging Challenge
Inside the box is a real mix of goodies, including:
- A lavender and geranium candle
- A double-walled glass mug and chamomile tea
- Pillow mist and relaxation oils
- A luxury sleep mask
- A journal and guided experience materials
With items in all sorts of shapes, sizes, and levels of fragility (especially the glass mug and candle), the packaging had two main jobs: keep everything safe in the post, and make sure opening the box feels calm and clutter-free.

Crafting the Bespoke Foam Insert
Working closely with Rachael and Michelle, we designed a custom insert using high-quality black foam.
Every single item gets its own dedicated spot, cut to the exact size of the product. That keeps the fragile bits snug and secure, while giving the whole box a clean, considered look. We cut the inserts on our CAD-operated waterjet machine... no lasers or blades needed, just a jet of pure water that leaves a clean, dust-free finish.
It’s been great working with a local business that cares so much about the little details of their customer experience and we wish them the very best as they grow! Visit Unfold's Website!

