At Kentucky Paper Box, we specialize in providing innovative solutions for the most challenging packaging products.

In the project highlighted here we worked with an entertainment industry customer to develop a packaging application in the form of a book style box set. The design included a tight wrapped rigid tray with a turned-edge cover. It also utilizes a panel and spine that is glued to create a hinge. The rigid tray is composed of .060 black chip board, while the exterior and the turned edge cover is printed four-color process with a matte UV coating, applied to 80 lb. premium coated one-sided stock. The rigid tray also included Mylar stay tape.

This project puts in perspective the diversity of manufacturing processes that we possess, and the comprehensive nature of our service offerings. This is a complete turnkey project that combines two very different manufacturing processes to create this high-end box set. The rigid tray was produced on our automated box line, and the turned edge cover on our automated laminator/case maker. To maximize output and quality we also developed a custom automated gluing/pack out system. This allowed us to maintain a high level of quality and repeatability regardless of order volume, in fact we were able to attain zero defects, while providing industry leading lead times.

One of the key factors to our success in work such as this is our dedication to quality and process flexibility. In this case we provided full compliance with the customers ISO program. As a result we now produce 100% of this customer’s work, this job alone represent volumes of up to 600,000 units annually, at lead times of just two weeks per release.

To learn more about this project, or the processes used to complete it, see the table below or contact us directly.

Project Description

Entertainment Packaging Application, Book Style Box Set

Capabilities Applied/Processes


  • Tight Wrapped Rigid Tray
  • Flat Board Turned-Edge Cover
  • Glue Rigid Tray to Third Panel and Spine Creating a Hinge


  • Custom Hot Melt Glue System
  • Polybag Machine
  • Custom Pack
Equipment Used to Manufacture Part
  • Rigid Tray – Emmeci Automated Box
  • Line Turned Edge Cover – Emmeci
  • Automated Laminator/Case Maker
Overall Part Dimensions

6 x 5 ¼ x 3 Overall

Tightest Tolerances

+/− 1/32”

Material Used

Rigid Tray:

Board: .060 Black Chip
Exterior Paper Print 4 C/P & Matte U.V. on 80#
Premium C1S Stock Mylar Stay Tape

Turned Edge Cover:

Board: .070 Sta Square Unitized
Print 4 C/P & Matte U.V. on 80# Premium C1S Stock

Industry for Use

Music & Entertainment Industry


400,000 to 600,000

Delivery/Turnaround Time

2 Weeks Per Release

Delivery Location

Northeast U.S.

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