How Sonhab Chocolate Traded Hand-Wrapping for Wholesale Growth

For a small-batch food brand, packaging is where craft meets the realities of running a business. It has to protect a delicate product and tell the story behind it without eating the hours a two-person team needs for the making itself. Sonhab came to PakFactory with a clear brand and three problems to solve.

• Was handmade packaging capping growth?
  Cutting, printing, and wrapping bars by hand ran to over 11.5 hours for every 100 bars, time the team could not spare.
• Could the box tell the sourcing story?
  The old wrap looked nice but left no room to explain how the cacao was grown and sourced.
• Would the right partner fit the budget?
  After a month of researching packaging companies and suppliers, Sonhab needed quality it could afford.

“

As soon as we posted our new packaging, we had stores following up asking to stock us. We have a list of shops right now on our waiting list.

”

Kristen Blue

Founder at Sonhab Chocolate

Kristen came to us having already worked with a designer, so we could move straight to 3D renderings and refine the details together. We landed on an envelope-style box with a latch that seals without any adhesive, which goes together in a fraction of the time hand-wrapping took.

The box is a textured, uncoated paperboard, a surface that prints cleanly and still takes a handwritten note, so Sonhab could keep the handcrafted feel while finally making room for the sourcing story and a promotional insert. Foil stamping and a subtle emboss gave each bar a premium, crafted finish worthy of the beans inside.

Before anything went to production, we caught design errors that would have meant costly reprints and double-checked every measurement, so the first run came back right. That care let Sonhab move into wholesale with confidence, and it soon came back for another run across an expanding range of bars.

Foil stamping & embossing

Envelope style box

Uncoated textured paperboard

Custom insert card

The finished box does what hours at the wrapping table never could, presenting the chocolate cleanly while still leaving room for a personal touch. Freed from wrapping bars by hand, Kristen and Cody moved into wholesale, and the stores kept coming. When packaging stops being the bottleneck, a growing brand can finally spend its time on the thing it does best.