Continuous Packaging Improvements Increase YOY Savings, Sustainability | Healthcare

1/24/2025

RRD Asia's packaging solutions yield cost-effective, plastic-free packaging for leading oral care company

CHALLENGE

A leading oral care company, known for blending technology with sleek design, offers smart electric toothbrushes and oral care products. As the brand grew, they desired packaging that reflected simplicity, health, and sustainability. 

The company sought a partner who could help optimize their packaging while meeting sustainability and cost-reduction goals. The specific challenges they needed to address included:

• Cost reduction: Achieving reductions in packaging costs while preserving a premium brand image and product integrity
• Sustainability: Developing eco-friendly packaging solutions to minimize environmental impact, including the use of sustainable materials, environmentally conscious inks, and smaller packaging sizes
• Quality maintenance: Maintaining high standards to provide a premium out-of-box experience for customers
• Production transition: Quickly adapting to production relocation in Southeast Asia, managing changes in decision-makers, and sustaining cost-saving initiatives

SOLUTION

The company partnered with RRD Asia to develop packaging solutions that aligned with these principles. RRD Asia implemented a phased approach to develop sustainable and cost-effective packaging solutions, achieving year-over-year evolution of the company’s packaging through five distinct generations:

• First generation: The initial packaging was a rigid board tube design, resulting in large sizes and high costs. RRD Asia transitioned to molded pulp, eliminating plastic, reducing packaging size, and lowering material and freight expenses.
• Second generation: Building on the molded pulp packaging, in the second generation, RRD Asia focused on reducing the overall footprint of the packaging, creating compact and eco-friendly packaging and thus reducing overall material and freight costs.
• Third generation: Paper hang tags were introduced, enhancing the design’s functionality and shelf appeal. Enhanced pulp trays maintained the brand’s premium image, while color management expertise helped to make the packaging look vibrant and high-quality on the shelf.
• Fourth generation: The transition to paper and corrugated trays aligned with European sustainability standards (AGEC-No.2020-105). Mineral oil-free inks were adopted, reducing environmental impact while preserving the high-end look of the packaging.
• Fifth generation: The latest packaging innovation focused on a streamlined design that reduced the number of components. A new sleeve box and single-piece paper pulp tray increased efficiency, reduced costs, and minimized environmental impact. RRD Asia also introduced novelty inks for a unique, market-differentiating feature, further strengthening the brand’s identity. The unique design became a standout feature in the market.

RESULTS

The collaboration with RRD Asia led to significant achievements in sustainability, cost reduction, and operational efficiency, and maintained the premium standards essential to the brand’s identity. Benefits included:

• Sustainability: All packaging is now made from 100% eco-friendly, recyclable materials. Smaller packaging sizes have reduced transportation costs and carbon emissions, aligning with the company’s sustainability goals.
• Cost reduction: Over the five packaging generations, total material and freight costs were reduced by an estimated 50%
• Innovative unboxing experience: The introduction of a one-pull unboxing design enhanced consumer engagement, driving increased sales through a more visually appealing and interactive packaging experience.
• Maintaining premium quality: Despite substantial cost reductions, RRD Asia has upheld the company’s high-quality standards, maintaining an exceptional out-of-box experience.
• Brand impact: The new sustainable and compact packaging not only helped achieve cost-reduction and sustainability goals but also reinforced the company’s image as an eco-conscious, forward-thinking leader.
• Expanded production: In addition to China, RRD Asia expanded production and supply of packaging materials to Southeast Asia contract manufacturers, supporting growth and optimizing supply chain costs.