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Success Story  /  Case 01Packlic × Sorlet

Custom packaging case study

Sorlet

Handmade hats & berets

“Style as unique as your history”

Sorlet emerald green custom corrugated hat box with a gold-foil monogram and a plastic carry handle
01

The brief

A custom hat box has one hard job most packaging never faces: it has to protect a soft, wide-brim shape all the way through the postal network and still feel like part of the gift when it lands. Sorlet is the atelier of Valentina Teran, handmade hats and berets sold under the line “Style as unique as your history.” Her customers expect the box to feel as considered as the hat inside it, so a plain shipper was never an option.

Valentina came to Packlic with a shipping problem. Her existing corrugated stock was too thin, hats arrived crushed or dented, and a brown box said nothing about a brand built on craft and ceremony. She needed a single custom hat box that could do two jobs at once: survive the carrier network, and deliver a premium, gift-like unboxing that customers would want to photograph and share.

Sorlet custom hat box, opened, protecting a wide-brim hat
The finished custom hat box, opened
02

The issues we solved


01
Challenge

Hats arrived crushed and dented in flimsy corrugated stock.

What we did

We upgraded to a sturdier corrugated mailer with a heavier flute that holds its shape through shipping and cushions a wide-brim hat on every side.

02
Challenge

A plain brown box did nothing for a premium, handmade brand.

What we did

We designed a foil-stamped emerald and gold box with a die-cut window and a floral-lined interior that carries a personal note, so the packaging reads as Sorlet from the very first glance.

03
Challenge

A full custom run is a big outlay for an independent maker.

What we did

We split the project into flexible installments, so upgrading her packaging never became a cash-flow burden and she could start with a manageable first run.


03

Dieline & structure


Sorlet hat box dieline, box outside: a 35 by 35 by 10 cm emerald corrugated mailer with a gold monogram
35 × 35 × 10 cmFlat dimensions

Structure. The custom hat box is a printed corrugated mailer, tuck-front with a finger-hole and a plastic carry handle, engineered at 35 by 35 by 10 cm so a wide-brim hat sits flat without being compressed. It is built on the same custom mailer box construction we produce for shipping-first brands, tuned here for a fragile, oversized product.

Stock. We moved Sorlet off the thin board that was arriving crushed and onto a heavier flute, so the box keeps its shape through the carrier network and still feels premium in hand. If you are weighing boards for a similar project, our packaging materials guide explains how flute profile and thickness change how much protection a box gives.

Sorlet hat box dieline, box inside: floral line-art interior artwork

04

Designing the custom hat box

With the structure solved, the design had to earn the “premium” promise. The artwork carries Sorlet’s own palette of deep emerald and gold: the monogram is foil-stamped on the lid above a die-cut window, and the interior is lined with hand-drawn florals and a personal thank-you note. Opening the box feels like receiving a gift, not collecting a parcel.

Every element was proofed before the run, from the gold-foil placement to the exact emerald ink, so the custom hat box that shipped matched the 3D mockup Valentina signed off. Small touches, like the finger-hole that doubles as a carry point, keep the unboxing effortless without adding cost.

Emerald#254E36
Gold#FCD581
Kraft#BAA685
Ivory#FFFFFF

Sorlet custom hat box interior with foil monogram, florals and a hand-written note
The custom hat box interior, with foil monogram, florals and a hand-written note
05

Production & unboxing


Sorlet emerald green custom corrugated hat box with a gold-foil monogram and a plastic carry handle
Sorlet custom hat box interior with foil monogram, florals and a hand-written note
Sorlet custom hat box, opened, protecting a wide-brim hat

The outcome

“Awesome experience working with Packlic. The team was patient, understanding, and went above and beyond to help me through the process.”

Valentina Teran · 5-star verified review on Trustpilot
Ship-safeSturdy in transit, premium in hand

The result is a single custom hat box that ships safe and unboxes like a keepsake, protective enough for the postal network and beautiful enough that customers photograph it before they even try the hat on. From dieline to gold-foil proof, Packlic managed the whole journey: structure, artwork, 3D mockup and production. If you are packaging something fragile or premium and want the same outcome, you can start your own project with a free 3D mockup and a real quote in 24 hours.

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