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ZYN’s stock tin is injection‑moulded plastic: cheap, light,and designed to be discarded after a single use. Replacing it with CNC‑machined aluminum packaging introduced three intertwined hurdles:

1. Geometry paradox – The client wanted the bottle opener dead‑centre on the can’s     underside. Standard pry‑bar profiles need an exposed edge; a sealed disc     offers none.
2. Capacity constraint – The new can had to hold exactly 15 nicotine pouches—no     user should sacrifice convenience for style.
3. Weight & cost balance – Aluminium brings premium tactility but threatens     pocket weight and machining minutes, which can balloon unit costs.

Failing on any front would reduce the product to a novelty gimmick rather than a flagship merchandise piece for a crypto‑savvy audience.

In five business days pkgd.design delivered two fully manufacturable versions:

• Debossed lid – streamlined feel, lower tool wear, and projected unit cost of $X.
• Embossed lid – mirrors the client’s original concept, adds X g mass and ~X % extra machining time.

Both variants matched the original plastic tin’s outer dimensions within ±0.05 mm, retained full 15‑pouch capacity, and arrived with STEP files, cutter‑pathn otes, and ISO‑dimensioned drawings any CNC shop could run immediately.

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