How To Make Accessories Box For Facial Brush

We often encounter a situation: the customer has only a general idea at the beginning but does not know what his specific needs are.

At this time, we will provide various possible solutions and suggestions based on our experience, and then in continuous communication, gradually the customers are more and more clear about their needs, and finally, we will find a satisfactory solution.

The following is a case, we helped a Canadian customer develop a packaging solution for an accessory box.

Case Background

This Canada customer has purchased one set facial cleansing brush product at the end of 2018, in the process of selling, many consumers want to buy the extra brush heads for replacement. So the client wants to develop a new kit of 3 brush heads to match the sales of the machine.

(For the convenience of description, we refer to this customer as S here.)

The Cutomer's Request

Make a rectangular box with three brush heads side by side.
Three brush heads can be seen outside.
The customer prefers to have a single-color printed box with a white background.
The box material is not confirmed.

To find a packaging solution, we have to consider how the product is placed inside (this is related to inner auxiliary packaging materials) and also how the outer color box would be. Below we will analyze this case from these two aspects.

Regarding how to choose the inner auxiliary packaging materials and outer box, please refer to our article “How to choose the right packaging for a customized beauty instrument product?”

How did we accomplish this work?

After analysis, our team believes that we must confirm the box shape and material firstly, which decides the whole packaging solution. However, S told us both are pending and they could not give a clear or detailed request. So the placement of the 3 heads needs to be determined first.

The confirmation of 3 pcs brush heads placement

We checked some brush heads accessory boxes on the market, Basically, the heads are held by a blister tray and then put into an outer box. If we follow this way, a new blister tray mold needs to be opened, which will not only increase the cost but also the MOQ of such a small blister tray will be very high.

S mentioned that he did not want to make a new blister tray mold, so we have to find some other inner packaging solutions for him.

Our designer immediately proposed two other inner packaging solutions: cardboard pallets and die-cut pallets.

Option A: Cardboard Pallets

Use a tray to hold the three brush heads, and the material of the tray can be the same as that of the outer box. The material can be cardboard or PET (plastic).

Option B: Die-cut pallets

Use EPE cotton board or EVA board to punch into holes to embed the three brush heads, and take them out directly when using them. However, we considered that this method would cause the entire brush heads to be trapped in the tray, and it is inconvenient to take the brush heads out. Moreover, the brush head is wet after use and needs to be ventilated to dry. This method is also not suitable. We made a detailed explanation to the customer.

After providing the two options to the customer, he chose the cardboard pallet, which is option A. So the placement of the brush head is determined.

Confirmation of the box shape & printing

At the very beginning, S put forward two requirements for the outer box: the three brush heads can be seen from outside; he requires a color box with white background. Based on this request, we propose the following options:

Option A：Window color box

The consumers can know the brush heads through the window, and the color box can be with a white background. We sent below pictures to the customer for reference:

Option B：Transparent PET color box

Use a transparent PET color box and the area that does not need to show the brush heads can be printed in a single color on a white background. (We also advised the customer that the cost of a PET box is usually higher than that of a color box.)

After communication, S chose the PET box, but at the same time, he put forward a new requirement: the box needs to be with matt-surface material, and he does not like glossy surface boxes for brush heads.

We know that the PET material used as a packaging box is generally with a glossy surface. Our purchaser checked with a few packaging suppliers and confirmed this point. One supplier suggested using PP material for a matt surface plastic box. (The box made of PP material is similar to the following picture.) However, such a box will have a defect, that is, there will be obvious white creases at the edge of each side. And if we make windows on the box, it looks not so beautiful.

After several rounds of communication, we confirmed the size of the entire package, but the customer still did not decide which option to use. We felt that S seems to be more concerned about the costs.

At this time, S asked us to offer individual costs for three different materials of cardboard, PET box, and PP box.

Proofing & Sending Samples

We quoted the prices of three different material boxes, at the same time, to make the customer know the box better, we decide to make some samples for him, of course, with paper material. As we are not sure of the customer’s preference, so we printed two shapes samples of the same size but with different opening methods, and sent them to the customer:

A display box, you can take out the brush heads directly after opening the box.

A push-pull box. After opening the box from the side, you need to pull out the inner tray and then take out the brush head.

In order to let the customer know more about the other two materials and understand our previous communication more clearly. Some PET and PP boxes reference samples were sent with the two white boxes together:

Sample 1: Matt PP box, to let the customer understand the characteristics of this PP material.

Sample 2: PET box with an outer protective film layer, this is to let the customer know the condition of the box when the mass production is finished.

Sample 3: PET box without an outer protective film, this is to let the customer know what the PET box looks like when consumers get it.

I still remember it’s the last working day when we sent out the samples. The 2019 CNY holiday will begin soon, it’s a bit cold in that afternoon, and few people in the office building.

The Final Solution

The customer’s feedback was received in February 2019. S said that he was very satisfied with the samples received and believed that the paper box had met all his requirements. We are all happy to know that. He asked some slight changes for the size of the window and the box. Our designer then gave the die-cut to him, and the design was completed soon.

After that, the replacements of 3 brush heads order was quickly confirmed, and also with a repeated order for the face brush.

Conclusion

The beginning of every customized solution is a rough idea, how to turn this idea into a real solution requires the joint efforts of you and us. With communication and quotations again and again, we will know each other better. Come and contact us, we look forward to working with you!