Case Study
Luxury Packaging
Costa Coffee case study: a tactile sleeve texture that holds up at scale.
Costa Coffee's branded sleeve is one of the most-handled packaging touchpoints in the UK. ERL developed and engraved the embossing roller specification behind that texture so the finished sleeve felt consistent, premium and unmistakably on-brand across high-volume production.
Application
Branded coffee cup sleeves
Focus
Tactile brand consistency
Process
Pilot trial before production tooling
The challenge
The Costa sleeve emboss had to feel deliberate and premium on every cup, not just in concept visuals or early samples. The pattern needed to translate cleanly onto the live substrate and repeat reliably across long production runs.
ERL's approach
ERL worked from the brand intent, developed the embossing pattern through pilot trials on the actual sleeve material, and refined the roller specification before committing full production tooling. That closed the gap between design intent and what the line would really produce.
The outcome
The final emboss delivered a clear tactile signature on a heavily handled pack format. The result was a repeatable branded texture that supported Costa's premium presentation without introducing uncertainty at production stage.
What ERL delivered
Precision tooling built around the real production requirement.
Each project relied on the same core principle: the embossing roller had to work in production, not just look right in a presentation or first sample. That means matching the pattern, engraving method and cylinder specification to the substrate, line conditions and finish expectation from the outset.
For brands where tactile quality is part of the product experience, that discipline is what turns an emboss from an aesthetic detail into a reliable manufacturing asset.
Project deliverables
Pattern development aligned to the sleeve substrate and converting conditions.
Pilot emboss sampling before the final production roller was committed.
Production engraving for consistent repeat and depth across volume manufacturing.
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From initial concept through to final roller delivery, our highly-experienced engravers provide expert guidance at every stage substrate selection, pattern development, tolerances and surface finish.
Contact details
ERL — Birch Mill, Heywood