Rigid Box Failure Analysis

Oct 08, 2026

Packaging Engineering · Engineering Case

Rigid Box Failure Analysis Case Study: Film Delamination

A project-based case study showing the packaging requirement, the development decision, the quality-control focus and the reported project result.

Project Overview

Application	Premium chocolate gift box
Box Structure	Two-piece rigid box
Board	1200gsm rigid board
Outer Paper	157g coated paper
Insert	Black flocked EVA
Finishing	Full color, scratch-resistant film, gold foil
Main Concern	Bubbling / film delamination
Root Cause	Adhesive incompatible with scratch-resistant film
Improvement	Dedicated adhesive + adjusted pressing temperature
Result	Issue solved; batch stable; client resumed/reordered

The Challenge

The finished box developed bubbling and film delamination.

Structural & Material Solution

The root cause was identified as adhesive incompatibility with the scratch-resistant film. A dedicated adhesive was selected and pressing temperature was adjusted.

Key Improvement

The corrective action addressed the material/process interaction instead of only treating the visible surface defect.

Quality Control

Checks focused on film adhesion, surface appearance, pressing conditions, gold foil, paper wrapping, EVA and batch consistency.

GooinPack's current packaging workflow places quality control after approved requirements, sampling and production. Current QC information covers materials, printing, dimensions, structure, finishing, insert fit, assembly and final inspection. View Packaging Quality Control.

Project Result

Issue solved; batch stable; client resumed/reordered

Final Packaging Configuration

Application	Premium chocolate gift box
Box Structure	Two-piece rigid box
Board	1200gsm rigid board
Outer Paper	157g coated paper
Insert	Black flocked EVA
Finishing	Full color, scratch-resistant film, gold foil
Main Concern	Bubbling / film delamination
Root Cause	Adhesive incompatible with scratch-resistant film
Improvement	Dedicated adhesive + adjusted pressing temperature
Result	Issue solved; batch stable; client resumed/reordered

Related Packaging Engineering

This case should be read together with the technical resources below. The case documents the project; the engineering resources explain the broader manufacturing principle. Our 8-Point QC Checklist for Luxury Boxes What Should You Check Before Approving a Packaging Sample? How to Compare Magnetic Box Quotes

Related GooinPack Capabilities

Custom Rigid Boxes · Custom Magnetic Boxes · Custom Packaging Process · Request a Packaging Quote

Need a Similar Custom Packaging Project?

Send your product dimensions, quantity, packaging structure, artwork or reference images. GooinPack can review the requirements before production.

Request a Packaging Quote

Project-specific dimensions, materials, MOQ, lead time, pricing and documentation should be confirmed against the approved quotation and production specification. This case study records the project information stated above and should not be interpreted as a universal packaging standard.