How Kumar Printers Is Helping Global Brands Achieve Packaging That Performs, Looks Premium, and Costs Less
Real case studies across rigid box, folding carton, corrugated box, blister cards, and sustainable packaging redesign reveal why leading brands trust Kumar Printers as their B2B packaging and printing solution partner.
Manesar, Haryana | June 2026
Kumar Printers Pvt. Ltd., one of India’s most established B2B packaging and printing manufacturers, is releasing a series of real-world case studies that demonstrate how the company has consistently solved complex packaging challenges for global brands without sacrificing quality, shelf appeal, or cost efficiency.
From rigid box luxury packaging for Glenfiddich and Gillette, to folding carton innovation for Britannia and Himalaya Ayurveda, to corrugated box and blister card solutions for personal care and healthcare brands, these case studies represent the depth and versatility that defines Kumar Printers as a trusted B2B packaging and printing solution provider with over six decades of proven execution.
The cases span sustainability-driven material substitutions that delivered up to 77% process cost reductions, premium printing and finishing techniques that solved registration and scuff-resistance challenges others could not crack, and structural redesigns that eliminated non-recyclable components while maintaining full product protection. Together, they form a clear picture of what brands can expect when they work with Kumar Printers.
The Business Case for Choosing the Right Packaging Partner
Packaging is one of the most visible and consequential cost lines for consumer brands. It is also one of the most underestimated sources of competitive advantage. The right packaging and printing solution does not just protect a product. It communicates brand value, drives purchase decisions at the shelf, reduces supply chain waste, and increasingly determines whether a product meets the sustainability requirements of global retail buyers and regulatory bodies.
Kumar Printers has built its reputation by understanding this comprehensively. With two manufacturing facilities in Manesar (Haryana) and Indore (Madhya Pradesh), a Heidelberg Speedmaster CX 104 press that is the first of its kind installed in Northern India, and certifications including ISO 9001:2015, ISO 14001:2015, BRC IOP Grade 6, FSC COC, and GMI, the company brings enterprise-grade capability to every client engagement, regardless of order scale.
CASE STUDY 01
Himalaya Ayurveda Soap | Folding Carton | Foil Elimination with No Visual Compromise
The Challenge
A leading personal care brand wanted to replace gold hot foil stamping on their soap folding carton with a more sustainable and cost-efficient alternative. The requirements were straightforward but technically demanding: reduce cost, eliminate plastic-laminate foil, improve recyclability, and do all of this without any visible degradation in shelf appeal or brand perception.
What Kumar Printers Did
The team replaced the traditional gold hot foil with gold ink applied through gravure printing, a process that delivers the same visual metallic warmth without the plastic film substrate that makes conventional foil non-recyclable. The execution required solving two precision challenges simultaneously: preventing ink peel-off (resolved using textured UV coating) and achieving exact registration alignment across three separate print processes, specifically offset printing, gravure printing, and embossing, running in a single sequential job.
Results
Process cost reduction: 77%
Total carton cost reduction: 20%
Recyclability: Improved (foil eliminated from carton structure)
Scuff and abrasion resistance: Enhanced (textured UV coating performs better than laminated foil)
Lead time impact: None (no increase to production schedule)
This case is a direct proof point that premium printing and finishing does not require premium materials to deliver premium results. The combination of process engineering and material substitution gave the brand a more sustainable carton at a materially lower cost, with better physical performance.
CASE STUDY 02
Gurkha and Guns Whisky | Rigid Box and Folding Carton | Plastic Sticker Elimination
The Challenge
An innovative whisky brand from Nepal approached Kumar Printers with two distinct packaging needs. First, the carton needed a natural wood-grain appearance to visually reference the oak barrels used in the maturation process. Second, the brand wanted to eliminate the circular plastic Gurkha logo sticker that was being manually applied to each carton, replacing it with something equally premium but free of plastic, more consistent in application, and operationally simpler.
What Kumar Printers Did
For the wood-grain effect, the team created a convincing textured wood finish on the surface of the folding carton through the precision application of matte coating. A portrait of the brand mascot was foiled directly onto the front panel using hot foil stamping, delivering the premium brand mark the client required.
For the sticker elimination brief, the plastic circular sticker was replaced with an embossed and foiled logo applied directly onto the carton surface in a single production pass. The logo artwork was highly detailed, which required a custom-engineered combined 3D embossing and foiling tool to achieve both depth and registration in one operation.
Results
Sticker process cost: 100% eliminated
Total carton cost reduction: 11%
Plastic usage: Reduced (sticker substrate fully removed)
Carton recyclability: Improved
Manual sticker application: Eliminated (improved line consistency and throughput)
Lead times: Reduced
This case demonstrates Kumar Printers’ ability to combine creative problem-solving with precision tooling engineering, turning a sustainability and cost brief into a packaging that actually looks better and performs more reliably on the production line than the solution it replaced.
CASE STUDY 03
Venus Snap by Gillette | Rigid Box | Foam Insert Substitution with Full Protection Retained
The Challenge
Gillette’s Venus Snap product required a packaging solution that held a compact hair remover pod and three spare razor blades securely during transit while presenting a premium unboxing experience at retail. The existing foam insert approach needed to be replaced with an environmentally preferable alternative, but the replacement had to pass the same drop-test standards as foam without increasing cost or lead time.
What Kumar Printers Did
The Kumar Printers team designed and manufactured a custom rigid box using 6-colour printing on art paper pasted over kappa board, producing a durable structure with vivid, high-contrast colours. Matt BOPP lamination was combined with UV gloss ink to create a textured contrast finish that gives the pack its premium shelf presence.
For the internal structure, foam inserts were replaced with a precision die-cut paper compartment engineered from FFB (Folding Flat Board) paperboard. The upper compartment holds the Venus Snap pod snugly in place; the lower compartment secures the three spare blade units. Drop-test compliance was achieved through precise engineering of compartment geometry and board weight, not through any compromise on recyclability.
Results
Process cost reduction: 36%
Total carton cost reduction: 8%
Plastic usage: Reduced (foam substrate eliminated)
Recyclability: Improved
Drop test compliance: Maintained (full protection standards met)
Foam cutting and gluing operations: Eliminated
Lead times: Reduced
The Venus Snap case is an example of structural packaging engineering applied to solve a sustainability brief without the typical trade-off of cost increase or performance compromise. The result is a rigid box that looks more refined, is more sustainable, and is cheaper to produce than what it replaced.
CASE STUDY 04
Glenfiddich 2020 Limited Edition | Rigid Box | Export-Grade Luxury Packaging
The Challenge
William Grant and Sons required a limited edition rigid box for the Glenfiddich 12 Year Old’s 2020 special release. The pack needed to communicate the brand’s 133-year heritage while reflecting the edition’s theme of “embracing change since 1887”. The quality standard had to meet the expectations of a luxury whisky consumer in export markets, requiring exceptional surface consistency and finishing precision.
What Kumar Printers Did
The Kumar Printers team created a multi-layer printed rigid box that combined spot UV, gloss UV, matte UV, raised UV, and metallised printing techniques in a single cohesive pack. The iconic Glenfiddich stag was highlighted on the front panel using spot UV to create dimensional contrast against the printed background. The multi-layer background itself used the interplay of gloss and matte UV finishes to create a visual sense of movement through time, referencing the brand narrative.
Contour lines referencing cartographic and historical maps were brought to life through raised UV embossing. The interior was engineered to securely hold the whisky bottle and a promotional whisky glass in position without movement during transit or unboxing. The overall specification required layering five distinct premium printing and finishing processes in precise registration across a rigid substrate, a technically complex execution.
Outcome
The pack was produced to export quality standards and delivered in brief. It demonstrated Kumar Printers' ability to manage multi-process luxury packaging at a level consistent with what is expected from premium international spirits brands, executing spot UV, raised UV, gloss and matte UV, and metallised elements in a single production workflow.
CASE STUDY 05
Pure Magic Chocolush by Britannia | Folding Carton | Multi-Finish Retail Packaging
The Brief
Britannia’s Pure Magic Chocolush biscuit range required a folding carton that captured the indulgent, sensory proposition of the product. The “Magic Moments” edition demanded a pack that conveyed richness through colour and texture at retail, competing effectively in a dense FMCG shelf environment while maintaining production efficiency at scale.
What Kumar Printers Did
The team applied 6-colour offset printing combined with gloss UV ink to produce vivid, saturated purple tones across the carton surface. A deliberate contrast between the gloss UV and the matte textured background finish created a layered visual depth that differentiates the pack from standard FMCG cartons. Brand name and text were rendered in gold embossing to add a tactile premium dimension that reinforces the “Magic” brand positioning.
Outcome
The carton was delivered on time at production volumes, balancing the complexity of multi-finish premium printing and finishing techniques with the throughput efficiency required for a mass-market FMCG client. The pack demonstrates that premium surface treatment is not exclusively the domain of luxury categories.
Sustainability Is Not a Feature. It Is the Operating Model.
Across all five case studies above, sustainability improvements were achieved as a consequence of engineering better packaging, not as a separate cost centre. The company holds FSC Chain of Custody certification, ensuring that all paper and paperboard sourced through its supply chain can be fully traced to responsibly managed forests. The majority of inks used across production are vegetable oil-based. Solid waste is disposed of exclusively through state-appointed authorities.
For brands that carry FSC, EPR Compliance, or Compostability certifications on their packaging, Kumar Printers provides the chain-of-custody documentation and process compliance required to substantiate those claims through retail audits and procurement reviews. These are no longer optional. They are procurement requirements from major global buyers.
In Their Own Words
“Our goal has never been just to print a box. It is to solve a packaging problem intelligently. Whether that means engineering a rigid box for a luxury whisky limited edition, redesigning a folding carton to eliminate foil and reduce cost by 20%, or replacing foam inserts with a paper structure that performs better in a drop test, we bring the same rigour to every brief. Sustainability and cost efficiency are not in conflict if you engineer the solution correctly.”
Sandeep Bhargava, Managing Director, Kumar Printers Pvt. Ltd.
What Kumar Printers Delivers Across Product Lines
Rigid Box
Kumar Printers manufactures premium rigid boxes for luxury spirits, personal care, electronics, and gift packaging. Techniques include spot UV, raised UV, gloss and matte UV contrast, hot foil stamping, 3D embossing, gold foiling, and custom internal die-cut compartments engineered for product protection and unboxing experience.
Folding Carton
High-volume folding cartons for pharmaceutical, FMCG, food, alcobev, and personal care clients. GMI certified for colour consistency. Produced on the Heidelberg Speedmaster CX 104, the first installation of this press in Northern India, running at 15,000 sheets per hour with AI-assisted spectral colour correction on every sheet.
Corrugated Box
Secondary and transit corrugated box solutions for automobile, electronics, and consumer goods sectors. Litho-laminated options available for retail-ready corrugated packaging that maintains brand visibility on the shelf and through the supply chain.
Blister Cards
Print-ready blister cards for healthcare, personal care, and consumer electronics. Designed to meet regulatory printing requirements while providing strong retail shelf presence. Kumar Printers appears in Google Search for queries including ‘blister card packaging’ (456 monthly impressions) and ‘printed blister cards’ demonstrating established market recognition in this category.
Premium Printing and Finishing
All product lines are supported by the company’s full range of premium printing and finishing capabilities: hot foil stamping, gravure printing, embossing, spot UV, gloss and matte UV, metallic inks, soft-touch lamination, textured coatings, and cast-and-cure processes. These finishing options are available to clients as tools for sustainable material substitution, brand differentiation, or both.
Ready to Discuss Your Packaging Challenge?
Kumar Printers currently serves brands across India and in export markets including the UK, USA, UAE, and Saudi Arabia. The company is a regional partner of the Global Packaging Alliance, a consortium of independent packaging manufacturers across eight countries including Brazil, Mexico, USA, China, and Korea.
Whether the requirement is a rigid box for a premium launch, a folding carton programme at pharmaceutical scale, a corrugated box solution for transit, a blister card for a healthcare product, or a sustainability redesign project that needs to reduce cost without reducing impact, the Kumar Printers team can identify a practical, tested solution backed by real case study outcomes.
To discuss a packaging brief or request a consultation, contact Kumar Printers at: [email protected] or visit www.kumarprinters.com
About Kumar Printers Pvt. Ltd.
Kumar Printers Pvt. Ltd. is one of India’s leading B2B packaging and printing manufacturers with over 60 years of experience delivering paperboard packaging solutions to the pharmaceutical, FMCG, alcove, automobile, garment, and personal care industries. Operating two facilities in Manesar, Haryana and Indore, Madhya Pradesh, the company converts more than 12,000 tons of paper and paperboard annually across five product lines: rigid box, folding carton, corrugated box, blister cards, and inserts and outserts. Certified under ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, BRC IOP Grade 6, FSC COC, GMI, and Sedex, and trusted by global brands including Nestlé, Gillette, P&G, Duracell, Colgate, Adidas, Volkswagen, Sun Pharma, and Dr. Reddy’s, Kumar Printers is a complete B2B packaging and printing solution partner built for the demands of global procurement.
Media Contact
Kumar Printers Pvt. Ltd.
Plot No. 24, Sector V, IMT Manesar, Gurgaon, Haryana 122050, India
Email: [email protected]
Website: www.kumarprinters.com
Sources and References
1. Kumar Printers Official Website: www.kumarprinters.com
2. Venus Snap Case Study: kumarprinters.com/venus-snap
3. Glenfiddich 2020 Limited Edition Case Study: kumarprinters.com/glenfiddich-2020-limited-edition
4. Gurkha and Guns Whisky Case Study: kumarprinters.com/gurkha-and-guns-whisky
5. Pure Magic Chocolush Case Study: kumarprinters.com/pure-magic-chocolush
6. Heidelberg India Press Release (June 2023): heidelberg.com/in/en/about_us/news/press_release_14592.jsp