Case Study: Reigniting the Wall of Flame
The “Wall of Flame” has always been a fiery focal point for California Tortilla, celebrating their impressive lineup of hot sauces. However, the original design—a traditional neon tubing sign housed in a heavy wooden cabinet—proved expensive, cumbersome, and impractical for widespread use. The challenge was to reimagine the sign with a more modern approach that maintained its visual impact while improving scalability, cost-efficiency, and ease of installation.
Our solution replaced the neon tubing with vibrant, layered printed acrylic and routed flame details, creating a contemporary illuminated design that still packed a punch. Engineered to ship flat and assemble effortlessly on-site, the new sign successfully modernized the look and feel of the Wall of Flame while enhancing functionality and reducing costs.
1. Concept and Design Development
From Neon Glow to Modern Brilliance
To transition from the traditional neon sign, we developed a layered acrylic design that utilized printed graphics and routed flame shapes to create depth and vibrancy. By incorporating modern illumination techniques, the new concept offered a contemporary aesthetic that honored the bold energy of the original while introducing a fresh and practical design approach.
2. Prototyping and Testing
Testing the Heat
During prototyping, we carefully tested the materials and lighting to ensure the layered acrylic design achieved the same bold, fiery impact as the original neon. This phase included refining the assembly process to ensure the sign could be shipped flat and easily installed, without losing its striking visual appeal.
3. Production and Implementation
Effortless Assembly, Maximum Impact
The final design was produced using high-quality printed acrylic and precision-cut flame layers, paired with modern LED lighting to achieve an impactful glow. The flat-packed components were designed for intuitive assembly and seamless installation, allowing franchisees to easily integrate the new sign into their locations.
4. Ongoing Impact and Monitoring
Modern Glow, Franchise-Wide
The Wall of Flame’s updated design has become a standout feature across California Tortilla locations. The sleek, illuminated sign offers a modern take on the original neon while simplifying installation and reducing costs. The feedback from franchisees and customers confirms its success as a vibrant and practical branding element that keeps the flame alive.
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