The Caraa program, part of Coterie Baby’s corporate gift initiative, presented a unique challenge with its black on black design for the outer box. The objective was to achieve a full coverage matte finish with a glossy appearance to highlight the company names of Caraa and Coterie. Flyleaf’s team faced the task of finding the optimal substrate and production process to meet these specific design requirements.

To tackle the challenge, Flyleaf experimented with different materials and conducted ink drawdowns to determine the most suitable substrate that would match the desired black color design. During the production phase, a dual-process approach was adopted. Flexographic printing was utilized to achieve the complete coverage of black ink, ensuring a uniform and consistent matte finish on the outer box. To add the glossy effect for the logos, digital printing equipment was employed, creating a striking contrast and highlighting the company names.

This collaboration between Coterie Baby and Flyleaf showcased the ability to overcome unique design challenges and deliver exceptional results. The Caraa program’s limited edition partnership boxes stood out with their sophisticated black on black design, offering a memorable unboxing experience for recipients and reflecting the brands’ commitment to quality and attention to detail.

Great Jones Goods, a direct-to-consumer kitchenware startup, had initially launched their business with a range of pots and pans. However, their one-size-fits-all packaging proved to be inadequate, leading to product damage during shipping, wasted space, and increased shipping costs. Seeking a solution to address these challenges and enhance their brand image, they approached Flyleaf for assistance.

The overall objective was to create custom packaging for their three main product sets: the Fully Baked Bakeware Set, Patty Cake Duo Set, and Breadwinner Loaf Duo Set. The primary goals were to ensure product protection during shipping, optimize space utilization, and provide a premium unboxing experience for their customers.

Coterie Baby reached out to Flyleaf for help with planning and producing their corporate gift program for expectant employees and clients. Our task involved creating a series of limited edition partnership boxes that was based on a rough design mock-up. The program is a collaborative effort between Coterie and corporate partners, and we are thrilled to be a part of it. Coterie’s first collaboration with Uber set the tone for their future partnerships. Coterie provided Flyleaf gifts to be included in the box, allowing us to create a modular prototype for Uber and other potential partners. After the prototype was finished, we incorporated graphical elements into the design and produced the box and collateral items.

For the Gift of Sleep Bundle in partnership with Parachute, we designed a two-tier unboxing experience. Opening the box revealed an eye mask, gift card, and Charlie the Bunny. A convenient tab allowed recipients to lift out a shelf, unveiling packs of diapers and a swaddle blanket. Flyleaf worked closely with Coterie to manage all print-related tasks, ensuring the production of high-quality print materials.

As an extension of Coterie’s team Flyleaf’s involvement in the project allowed for a seamless execution of the corporate gift program. The collaboration resulted in a memorable unboxing experience that showcased the partnership with Parachute and strengthened Coterie’s brand image.

Casper Sleep, a mattress-in-a-box start-up, rapidly expanded within a few years to become a multi-channel Sleep Company offering a wide range of sleep products. As their print and packaging needs grew, Casper sought the assistance of Flyleaf. What began with providing business cards evolved into a comprehensive partnership to support Casper’s transformation into a leading sleep destination.

Casper faced the challenge of managing their increasing print and packaging requirements amid overnight growth. To meet the surge in demand, Flyleaf developed a centralized Interface that organized all relevant information, facilitating easy onboarding of new partners and providing complete visibility into orders. With over 350 SKUs organized and tracked, Casper gained better control over their print supply chain and ensured smooth operations. Flyleaf’s strategic approach involved assessing order patterns and volume needs to tailor the production process accordingly. By proactively managing production and finding the right balance between print-on-demand and fulfillment-on-demand, Flyleaf reduced costs and improved response times. And, collaboration with our print partners ensured timely delivery of materials, enabling Casper to maintain their supply chain momentum.

The long-term partnership between Flyleaf and Casper Sleep has resulted in a deep understanding of Casper’s processes. Flyleaf acts as an extension of Casper’s team, providing independent management of day-to-day orders and anticipating their evolving needs. With Flyleaf’s support, Casper has experienced streamlined operations, minimized logistical challenges, and maintained a high level of customer satisfaction.

The Kate Spade brand is instantly recognizable for its “Live Colorfully” philosophy, which is evident in all of its products. The brand’s focus is on a world full of crisp colors, which is reflected in all aspects of their marketing campaigns. Kate Spade’s marketing strategies are meticulously crafted, with a mix of digital and physical events working together to achieve their objectives.

At Flyleaf, when undertaking a Kate Spade project, we understand that an exhaustive color profiling process involving ink drawdowns, color proofs, and press checks is necessary. However, the real challenge lies in ensuring materials are delivered to hundreds of thousands of homes within a very narrow timeframe. The effectiveness of print materials and direct mail campaigns is directly linked to the seamless coordination of all supporting elements. Given the significant human and financial resources that Kate Spade commits to these projects, the process is incredibly demanding, and the stakes are high for everyone involved.

What’s fascinating about coordinating a Kate Spade direct mail project is that they take anywhere from three to six months to finish, yet the printing aspect is accomplished within just a few days. Every project timing begins with the targeted in-home date, followed by detailed planning of each step leading up to the delivery of the mail piece. These steps include routing commingled mail to ten regional USPS facilities to receive postage discounts, ensuring correct formatting of mail addresses using data hygiene services, print production, and ordering premium ‘making size’ paper directly from the paper mill in order to minimize waste.

Many projects require both U.S. and Canadian versions, as well as specialized print services for various items such as stickers and custom bags. Additionally, these projects may require finishing touches of foil or spot varnish applications. Although print quality is undoubtedly important to Kate Spade, it is Flyleaf’s collaborative approach and transparent processes that keep all members on the same page. With numerous parties involved and months of planning, our system effectively allows for key information to flow between participants, as well as tracking and monitoring the progress of each activity throughout the entire process. And deliver within a tight timeframe.

In 2022, Ruani was founded by a first-time entrepreneur and a renowned pastry chef. The company’s focus is on producing healthier dessert options and launched a line of brownies with organic ingredients. Ruani presented Flyleaf with a distinctive product that boasted an array of flavors, each with its own distinct and dynamic color scheme. The challenge was to create customized retail packaging that held twelve pouches and matched the exact color of the flexible pouch packaging. It was crucial for Ruani to launch the business with a cohesive packaging design that emphasized the attention to detail and natural ingredients of their brownies.

Starting with receiving the pouches to determine dimensions and material suitability, we then proceeded to create a retail carton prototype packed with the pouches. This prototype was sent to Ruani for review, and simultaneous color profiles were developed for each brownie flavor. Once the prototype was approved, printed proofs were produced to ensure color consistency. All of this was accomplished within a two-week timeframe, demonstrating a commitment to timely execution.

In the manufacturing process, cost-effective delivery of the small volume order was made possible by efficiently producing three different cartons in a single digital print run. Additionally, laser-cutting techniques were utilized to eliminate the need for expensive cutting dies. It’s understandable that launching a brand involves juggling multiple responsibilities, and Ruani faced this challenge. In such cases, Flyleaf’s role becomes crucial in lessening the burden on the founding team, particularly when it comes to coordinating activities in areas where they have limited experience.

In the specific case of Flyleaf’s involvement with Ruani, there was an additional challenge posed by an unprecedented paper supply shortage. Despite this obstacle, Flyleaf took the responsibility of managing the situation and ensuring that the deliverables were completed in time for Ruani’s launch. Dealing with unforeseen supply chain disruptions requires adaptability and resourcefulness, and Flyleaf worked to find solutions that would meet the project’s requirements within the given constraints.

Regret nothing? The phrase might ring true in most cases but with few notable exceptions. Tattoos are one of them. Ephemeral Tattoo is a new kind of tattoo studio set to innovate on a 12,000-year-old craft with made-to-fade designs that last at least a year and sometimes up to three. Flyleaf initially worked with Ephemeral Tattoo on producing the Aftercare Kit that comes with every tattoo appointment and contains a pocket folder, aftercare instructions, a bookmark, and a couple of stickers.

Our partnership with Ephemeral has constantly evolved as we cater to their growing number of studios. However, the business presents unique challenges, particularly in managing their print supply chain. The primary obstacle is the need for specialized equipment and coordination with six different production facilities to create 13 items across five segments of print. This includes both domestic and overseas manufacturers. Despite the challenges, we are excited at the opportunity to manage Ephemeral’s print needs.

Flyleaf recommended a strategy that would ensure cost-effective and timely service to every studio. The plan involved collaborating with Ephemeral to forecast studio needs and producing a large volume of each item. This inventory would then be readily available for studios to order and Flyleaf to fulfill their requests. Ephemeral Tattoo is now able to organize thirteen SKUs and simplify their ordering process through Flyleaf’s shared interface. Additionally, Flyleaf is providing support to Ephemeral Tattoo in various print categories: commercial (aftercare instructions, bookmarks, and event cards), stationery (pocket folders), labels (bag seals and circle stickers), promo (pencils, balloons, and fabric pouch bags), and packaging (paper shopping bags); and managing inventory for rapid fulfillment of orders.

Launching a new product is an exciting experience, but it’s even more thrilling when it signifies the birth of a new company. Despite the challenges posed by the COVID-19 pandemic, the founder’s leukemia treatments, and the supply chain crisis, Jackfir overcame the obstacles and successfully launched the business in August 2022.

During our initial meeting, which took place a year and a half before Jackfir was officially launched, the founder established a crucial requirement: all print materials and production must align with the brand. Not only has the company employed a meticulously selective process for choosing skincare ingredients, but they’ve also carried this approach over to the design of their packaging, which reflects their vision and values.

To achieve these objectives, Flyleaf gathered materials for sampling purposes, built prototype packaging and dielines of all product sizes, produced a color matrix to ensure precise color matching, prepared pricing on multiple options, and coordinated the Forest Stewardship Council (FSC) certification approval. As part of the planning process, and consistent with Jackfir’s sustainability goals, print production occurred a short drive from distribution to minimize carbon footprint.