The challenge
Rabanne gift sets typically contain multiple components, including a fragrance bottle, deodorant spray and additional accessories. These elements need to be held securely in place while remaining clearly visible when the box is opened. Traditional plastic inserts provide structure, but do not align with long-term sustainability goals.
The packaging also had to integrate seamlessly into an existing rigid cardboard box and maintain the refined aesthetic associated with the brand. Any alternative material needed to support high-volume production without compromising consistency.
The PaperFoam® solution
PaperFoam® developed a custom-molded insert tailored to the exact dimensions of the Rabanne gift sets. Each product component has its own dedicated position, preventing movement during transport and preserving the presentation at retail and during unboxing.
The insert replaces plastic with a biobased material that is lightweight, shock absorbing and suitable for recycling with paper or composting, depending on local systems. This creates a clear end-of-life route without adding complexity for consumers. More information on material behavior is available on our recyclability and compostability page.
Design and presentation
The PaperFoam® insert is designed to sit flush within the rigid box, keeping the overall structure clean and balanced. Cut-outs follow the contours of each product, ensuring both stability and visual alignment. The neutral tone of the material allows the fragrance bottles and branding elements to remain the focal point.
Combined with the printed interior and exterior of the box, the insert supports a premium unboxing experience while quietly reinforcing the move away from plastic packaging components.
Impact and results
By introducing a PaperFoam® insert, Rabanne reduced the use of fossil-based plastics in its gift packaging. The lighter material also contributes to more efficient handling and transport throughout the supply chain.
This case shows how premium fragrance packaging can maintain a high-end look and feel while incorporating more responsible material choices. Similar luxury and cosmetics applications can be found in our portfolio.
Packaging for cosmetics and fragrance
Cosmetics and fragrance packaging often requires a balance between protection, presentation and scalability. PaperFoam® inserts are designed to work within existing box formats and packing processes, making them suitable for both limited editions and large production runs.
For teams exploring alternatives to plastic trays in premium packaging, evaluating material samples early helps align design and production requirements. Our premium sample kit allows brands to assess surface quality, fit and handling before moving into custom tooling.
Considering a similar packaging transition?
If your packaging requires precise positioning, a premium presentation and a reduction in plastic components, a custom PaperFoam® insert can be a suitable solution. Contact PaperFoam® to discuss your project or explore recent developments in our news section.
