
January 16, 2025
Double RL Whiskey Case Study
The Brief
IPL Packaging was commissioned by Ralph Lauren to develop packaging solutions for their Double RL Whiskey. The project began with two distinct design concepts requiring IPL’s expertise to refine and execute: a premium leather-styled case with a notebook aesthetic, and a vintage-inspired rigid board box.
Each concept needed to embody Ralph Lauren’s commitment to craftsmanship while meeting specific technical and aesthetic requirements and bringing the client’s vision to life.
The Challenges
The project presented several complex material and manufacturing hurdles:
- Initial genuine leather testing revealed inconsistencies in texture and debossing quality that compromised the desired premium finish.
- Material thickness specifications proved incompatible with production processes.
- Cost considerations for genuine leather threatened project feasibility.
- Achieving the exact aesthetic of Ralph Lauren’s design vision while ensuring manufacturability.
- Maintaining brand standards across different material choices and manufacturing techniques.


The Evolution
The project underwent two distinct phases. Initially, IPL developed solutions for both concepts:
First Phase Solutions:
- For the leather-style case:
- Engineered a PU leather alternative that met quality and consistency requirements.
- Enhanced design with decorative edge stitching.
- Integrated push-button snap closures.
- Developed a specialised EVA fitment with PU leather-wrapped surface card.
- For the rigid board option:
- Created a streamlined vintage-inspired design.
- Implemented specified branding elements.
- Maintained cost-effectiveness without compromising quality
Second Phase Development:
When the project resumed, the client’s vision evolved toward genuine leather with custom tooling. The design also underwent changes, transitioning from a plain design with logo to a more complex and detailed design pattern covering the entire pack and requiring multiple level emboss / deboss details.
IPL responded by:
- Conducting extensive material research and testing.
- Identifying sheepskin leather as an optimal solution.
- Developing specialized texture patterns that maintained consistency.
- Perfecting high-end stitching techniques
The Result





IPL delivered a premium packaging solution that married Ralph Lauren’s luxury aesthetic with practical manufacturability. The final sheepskin leather execution achieved the desired textural complexity and pattern definition while ensuring production viability.
Pre-production samples received approval in April 2024, with successful production completion and delivery by October 2024.
The project exemplifies IPL’s ability to navigate complex material challenges while maintaining unwavering commitment to client vision and quality standards. The final product stands as a testament to the successful collaboration between the client’s design ambitions and IPL’s technical expertise.
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