How Wells Dairy Was Able to Get Their New Product to Market Quickly
Wells Enterprises, one of the largest ice cream and frozen treats manufacturers in the United States, launched a new product line in club stores and asked Great Northern to design a package that would meet their needs.
The graphics needed to be of superior quality and catch the eyes of shoppers in the store. The package needed to function successfully through the entire process from printing and converting to fulfillment, distribution, and retail. It needed to be sturdy enough to endure the refrigerated and frozen environments it was going to live in and support the weight of the product when palletized without master cases. The package also needed enough structural integrity to withstand club store distribution systems. To confirm that the package performed properly on Wells’ new automated fulfillment line, machine trials needed to be done, including a final acceptance trial for the machinery before installation.
Great Northern engineered a stunning package that could withstand the rigors of shipping and distribution while also creating a billboard effect and attracting shoppers when displayed on a pallet in club stores. For efficient fulfillment, custom scoring profiles for the thicker substrate ensure the carton erects easily and squarely. Great Northern’s solution also helps retailers, as the packaging makes handling, cleanup, and disposal easier while creating a more sustainable package.
The Solution
Substrate
A 40 pt. laminated paperboard construction consisting of a 10pt. SBS top sheet from SAPPI and a 30pt. recycled base sheet was used
Construction
Our structure was specifically engineered to meet the needs of the customer for strength and functionality

Quality
Our operators and crews conduct quality checks throughout the converting process to ensure the product will perform as intended
Eye-Catching
This colorful, eye-catching package creates a more engaging shopper experience and an impactful billboard effect

The Bottom Line
Great Northern engineered a custom substrate for this package that performs exceptionally well to maintain package integrity in cold and damp refrigerated and frozen environments. The structural material strength meets club store requirements and withstands the weight of the product when palletized without master cases.
The thinner material allows for more cartons per truck, uses less warehouse space, and uses overall less material, which creates a more sustainable and less costly solution. Also, the specifically engineered scoring profiles for this 40 pt. laminate structure allowed the carton to erect and form successfully on the customers’ auto-forming equipment.
The simplistic but clean product image is prominent on all viewable panels of the package, creating a billboard effect in the store. The use of blue and white colors blends well with the branding of the Blue Bunny logo and contrasts nicely as the ice cream cups are brought to the forefront of the graphics. Finally, the overall graphics are accentuated by the high-finish, glossy look of the UV coating that was applied.
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