Opal Specialty Packaging is producing digitally printed mailer boxes for The Neighbours Cellar, combining protective board construction with the flexibility to run multiple gift designs in a single production run.
For personalised drinks gifting business The Neighbours Cellar, the packaging brief extended beyond getting bottles safely to their destination. The mailer also needed to complement the personalised contents and provide a consistent print finish across a varied range of gift designs.
The business began during the pandemic, when its founders sent a friend a bottle of wine featuring his photograph on the label to mark a birthday spent in lockdown. That gesture developed into a gifting service combining a chosen drink, photograph and personalised message.
To support deliveries across Australia, Opal developed two mailer formats. A single mailer holds one bottle, while a double mailer accommodates one to two bottles, or one bottle alongside additional gifts.
The outer packaging uses B-flute board, with an I-flute internal insert designed to support the contents and minimise bottle movement during transit. Opal says the combination provides the strength and rigidity required for transportation and delivery.
Print presentation was another consideration. Opal changed the exterior liner specification to deliver what it describes as a crisper, more refined print finish, while maintaining the strength and functionality required for the mailer.
Approximately 15 artwork designs are produced for each of the two box sizes on Opal’s EFI Nozomi C1800 digital printer. The technology allows multiple designs to be combined within a single production run, accommodating the brand’s range without requiring a separate run for each artwork.
Opal also tailored the production layout to The Neighbours Cellar’s order quantities to maximise sheet utilisation and print capacity. The company says this approach, combined with digital print flexibility and board selection, has helped achieve a lower packaging unit cost while accommodating varying quantities across multiple designs.
James Emery, co-founder of The Neighbours Cellar, said Opal’s capabilities supported its appointment as the business’s sole packaging supplier.
“We chose Opal Specialty Packaging as our sole supplier as they demonstrated they had the capabilities we needed to produce our range of gift boxes, across all of our packaging.”
The paper used to manufacture the packaging is supplied by both of Opal’s Australian paper mills. According to Opal, the board contains approximately 77 per cent recycled paper content, and the mailer packaging can be recycled through kerbside collection after use.
For The Neighbours Cellar, the production approach provides flexibility to offer a broad selection of gift designs across two box formats, supported by a locally manufactured paper supply.
