Leading carton manufacturer Falconer Print & Packaging has introduced a premium cartonboard pack for independent whisky bottler One Cask at a Time, merging luxury presentation, production efficiency, and sustainability tailored for the Scotch whisky sector.
Crafted specifically for One Cask at a Time’s standardized carton format, this pack significantly enhances shelf presence and tactile appeal, akin to high-end rigid presentation boxes, while simultaneously capitalizing on the commercial and environmental advantages of cartonboard.
The innovative eight-panel structure offers remarkable rigidity and an upscale aesthetic, further supported by an oversized format that stands out prominently in premium retail spaces. A recessed central panel allows for variable labels across different whisky expressions and age statements, thus enabling both production flexibility and economies of scale.
Manufactured using FSC-certified virgin fibre cartonboard sourced from Holmen, this fully recyclable pack represents a responsible alternative to heavier rigid formats, effectively eliminating the need for plastic vac-formed inserts. Its one-piece, flat-packed design enhances pallet efficiency, reduces transport volume, and facilitates expedited assembly on the bottling line.
Visually, the carton provides a highly sensory experience for consumers through the use of metallic inks, intricate hot-foil detailing, embossing, debossing, and contrasting gloss finishes. The end result is a packaging solution that exemplifies craftsmanship, exclusivity, and quality, while promoting consumer interaction. Falconer’s CAD team oversaw the structural design, with graphic design executed by Bombcrater.
Russell Bradley, head of brand development at One Cask at a Time, stated: “Falconer has been an absolute delight to work with throughout this project. From the earliest stages of development, the team demonstrated exceptional expertise, creativity, and attention to detail, delivering a finished pack that exceeded our expectations. The whole team have been professional, responsive and a genuine pleasure to work with and we are already exploring future collaborations together.”
Colin Pow, sales and marketing director at Falconer, added: “This project perfectly demonstrates how cartonboard can deliver the premium appearance and tactile quality expected within the luxury spirits sector, while also offering strong sustainability and operational benefits. By combining innovative structural design with high-end print finishes, we were able to create a pack that delivers real shelf impact without compromising recyclability or production efficiency.”
Falconer specializes in manufacturing decorative printed folding cartons across various industries, including pharmaceuticals, cosmetics, beverages, spirits, giftware, healthcare, veterinary, pet care, and luxury confectionery. The company is recognized for integrating high-quality added-value finishes and utilizing state-of-the-art equipment, enabling it to deliver exceptional packaging solutions and customer service.
For more information about Falconer and its extensive packaging solutions, visit www.falconerprint.co.uk.
