From Fragile Foil to Flawless Finish: How DHP Factory Engineered Medical-Grade Packaging

The client required a premium packaging solution that could meet the following challenges:

• Foil stamping along box edges must remain durable without flaking or peeling

• Black logo text needed to appear within gold foil areas

• High-value medical instruments required enhanced protection during transportation

• The packaging needed to maintain a professional, medical-grade appearance

After reviewing the client’s functional and branding requirements, DHP Factory developed a solution focused on process optimization and structural engineering.

To prevent foil peeling along the box edges, we adjusted the production sequence.

Printing and foil stamping were completed first, followed by lamination on art paper.

This allowed the gold foil to be sealed beneath a scratch-resistant matte film, significantly improving durability.

To achieve black logo text within gold foil areas, we applied a black printed color block beneath the foil area.

The color block was intentionally sized slightly smaller than the foil zone.

The foil plate was then hollowed out at the logo text area, allowing the black base color to show through.

This industry technique—similar to the “knockout” method—achieved the desired visual effect without adding extra production cost.

The client required a double-layer insert made from ultra-black high-density foam.

Finger cut-outs were precisely designed into the top layer, allowing users to easily lift the first insert layer while ensuring secure placement of the medical device.

The final packaging solution delivered improved durability at the box edges, enhanced visual precision, and reliable protection during shipping.

This case demonstrates how manufacturer-led process optimization can solve complex finishing challenges without increasing cost.