Choosing the right packaging for a product is one of the most important decisions a company can make.  At Pro Packaging, we have helped design and manufacture the best quality packaging options for over 35 years—both for new jobs and for re-design projects, such as the one illustrated here.  A leading flashlight manufacturer was looking to increase sales for one of their products; their current display box did not have any actual product visibility.  This customer approached us to help design and manufacture a new packaging solution.  Our long history of raising the visibility of products with innovative solutions, won us the contract.

We worked closely with our client’s creative services department to design new packaging that would fully display each flashlight.  Employing our state-of-the-art ArtiosCAD, SolidWorks, and Adobe Creative Suites software applications, we designed packaging that not only provided excellent visibility, but also a fresh new look for our client’s line of products.  The new packaging consisted of a fold-over trap blister card constructed with 20pt SBS board stock.  This card was offset-printed using a 6-color press and finished with a sparkling reticulated UV coating; a proprietary heat seal coating was applied to the inside of the card for a superior heat seal.  The package was then integrated with a clear PET clamshell blister for complete visibility.  Each box measured 4” in length by 10” in width and 1.25” in height, and was manufactured to tightest tolerances of ± 0.064”.

Our customer was impressed with our results, and ordered a total of 100,000 new display boxes for their flashlights.  The sales of these products subsequently increased, making this line of flashlights one of their most successful product re-launches.

Further details about this project are available below.  To learn more or to get a quote, please contact us directly.

Product Description

Display box for flashlights

Capabilities Applied/Processes


  • Consultation
  • Design
  • Prototyping
  • 6-Color Printing
  • Hot Foil Stamping
  • High Gloss Reticulated UV Coating
  • Heat Seal Coating
  • Die Cutting
Equipment Used to Manufacture Part

6-Color Lithographic Press with UV Coating
Die Cutter
Hot Foil Stamper

Overall Part Dimensions

Length: 4”
Width: 10”
Height: 1.25”

Tightest Tolerances


Material Used

Fold over trap blister card
20 pt SBS Board Stock
PET Clamshell Blister

Material Finish

Reticulated High Gloss UV Coating
Hot Foil Stamping
Heat Seal Coating

In process testing/inspection performed

Functionalities Testing
Visual Testing
Structural Testing

Industry for Use




Delivery/Turnaround Time

15-20 Days

Delivery Location


Standards Met

Customer Specifications, 2D CAD Drawing

Software Used

Adobe Creative Suites

Product Name

Display Box