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Sixto Packaging

Case Studies

Real brands. Measurable results.

From 2,500-unit DTC launches to 1.4M-unit recyclable migrations, here's how Sixto customers solve flexible packaging problems with us.

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  • Sparkling beverage flexible packaging samples with vibrant DigiPack-printed graphics

    Beverage · DTC

    From idea to shelf in 6 weeks for a sparkling beverage launch.

    Problem

    A founder-led sparkling beverage brand needed to launch four flavors with only 2,500 units per SKU — far below conventional flexographic minimums — and beat a 60-day retail commitment.

    Solution

    DigiPack short runs across all four SKUs on recyclable mono-material PE, with shared structure tooling and same-day digital proofs.

    Results

    concept to first ship
    6 wks
    plate or tooling cost
    $0
    at 2,500 units each
    4 SKUs
    recyclable substrate
    100%

    "DigiPack let us hit a retail window we would've missed by 8 weeks with anyone else. The cost-per-unit even at 2,500 was lower than our original flexo quote at 25,000."

    Mara Castellanos · Founder & CEO, House of Fizz
  • Specialty coffee pouches showing variable monthly designs printed via DigiPack

    Specialty Coffee

    12 monthly variants without 12 SKU minimums.

    Problem

    A specialty roaster's subscription program promised a unique pouch design every month — but flexo plate and minimum order costs would have eaten 40% of subscription margin.

    Solution

    Single mono-material PE pouch structure, with full artwork changing monthly through DigiPack variable data. Zero plate cost, 2-week ship.

    Results

    monthly designs / yr
    12
    packaging cost / subscriber
    –62%
    units per variant
    1,500
    subscriber retention
    +34%

    "Sixto turned what was a creative dream into a unit-economics win. Our retention jumped the quarter we started monthly variant pouches."

    Daniel Park · Director of Product, Northbeam Coffee
  • Recyclable mono-material pet treat pouches on a Sixto press floor

    Pet Food

    Switching a 1.4M-unit pet treat program to recyclable PE.

    Problem

    A premium pet treat brand needed to migrate from PET/PE laminate to a How2Recycle-ready mono-material structure without changing fill-line equipment or shelf-life claims.

    Solution

    Custom mono-material PE structure with EVOH oxygen barrier and PE-compatible zipper. Qualified on-line over a 5-week trial before full migration.

    Results

    units / year migrated
    1.4M
    shelf life maintained
    12 mo
    carbon per pack
    –22%
    store drop-off qualified
    How2Recycle

    "We expected to lose shelf life or break the fill line. We did neither. Sixto's engineers ran the trial like it was their own product."

    Priya Shankar · VP Operations, Wildkind Pet Co.

Patterns

What our case studies have in common.

  • Speed

    DigiPack cuts time-to-shelf by 60–80% vs. flexo for short runs.

  • Margin

    Lower per-unit cost at short volumes through eliminated plate charges.

  • Sustainability

    Recyclable substrate migrations without losing shelf life.

See how the underlying capabilities work — DigiPack, sustainability, capabilities.

Questions

Frequently asked questions

Can't find what you need? Talk to a packaging engineer.

  • Can I see references from brands in my category?

    Yes. Reach out and we'll connect you with references in food, beverage, pet, personal care, or cannabis depending on your category.

  • Will you share my brand in case studies?

    Only with your written approval. We're happy to feature your story or keep your name anonymous — your call.

Next step

Want a result like these for your brand?

Tell us about your project. We'll bring case studies, references, and a quote.

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