CASE STUDIES
Vape Cartridge Boxes for Blu
The Challenge
Blu, a leading e-cigarette brand, was facing packaging challenges with their vape cartridge boxes. Their original design featured a tray that held two cartridges and slid into an outer box, accompanied by a loose coupon card inside the box.
However, this setup presented two issues:
- Inefficient Pack-Out Process: The use of multiple components in the packaging was causing a slower than ideal pack-out process.
- Lost Coupon Cards: The loose coupon cards frequently slipped out before the end-user even opened the product.
To complicate matters, any packaging redesign had to comply with strict FDA regulations. Once a product’s packaging is approved by the FDA, any changes to its dimensions or weight require resubmission. Therefore, the redesign had to adhere to these limitations while solving Blu’s challenges.
FEATURES
SERIALIZED CODES
PERFORATED CARDS
INTEGRATED DIVIDERS
The Solution
Wynalda’s Design Team took on the challenge, crafting a solution that enhanced Blu’s packaging efficiency and secured the coupon cards, all while remaining within the FDA’s constraints.
The new design featured:
Streamlined Structure: A straight tuck carton with an integrated door panel and dividers replaced the inner tray and outer box. This simplified the packaging process, allowing for quicker and more efficient pack-out.
Coupon Card Integration: To prevent coupon loss, the card was integrated directly into the carton as a perforated section on the inside of the box, ensuring it stayed with the product until opened by the end-user.
The redesign maintained the exact external dimensions, style, and weight of the original packaging, avoiding the need for FDA resubmission. We paid careful attention to ensure that all components, including the integrated panels and coupon card, matched the previous packaging’s specifications.
Additionally, Wynalda’s IT team developed custom software to generate unique, secure coupon codes. This system ensured no duplicates and filtered out any potentially offensive codes. The codes were securely stored and made available for Blu to manage within their system.
The Results
The results of this redesign were transformative for Blu. The new packaging dramatically improved pack-out efficiency, eliminating delays and bottlenecks. The integrated coupon cards stayed securely in place, preserving promotional value and enhancing user experience.
To top it off, the redesign met all FDA requirements, sparing Blu the time and expense of resubmission. Blu was thrilled with the new packaging, leading to a long-standing partnership with Wynalda, with repeated orders for this successful design.
