A method for manufacturing a paperboard structure includes passing a paperboard substrate through a hot-hard calender to yield a calendered paperboard substrate, the hot-hard calender including a nip defined by a thermo-roller and a counter roller, wherein a contact surface of the thermo-roller is heated to an elevated temperature. The method then includes applying a basecoat to the calendered paperboard substrate to yield a basecoated paperboard substrate, the basecoat includes a basecoat binder and a basecoat pigment blend. The method further includes applying a topcoat to the basecoated paperboard substrate.