Category Archives for "Consumer Electronics"

Jaybird | Custom VIP Box | Packaging Case Study

Jaybird pioneered the Bluetooth wireless sports earbud and remains a leader in the space. They approached Process with the need to create custom VIP box packaging experience that would create an impact when delivering their newest line of earbuds to key influencers, ambassadors, and executives. We created a VIP unboxing experience by first starting with a matte black turned edge box. The box emulated their retail packaging in form but was enlarged to accommodate the multiple products that would need to be held inside. The graphic application to the outer box is purposefully understated with spot uv treated logos and a branded fabric puller. Once opened the recipient is immediately greeted with a screen printed acrylic sheet that sits flush with the top edge of the box. This sheet is meant to be a physical and visual hard stop and deliver key brand messaging. The acrylic sheet is then removed to reveal the product that is custom fit to the inside of the box using die-cut EVA foam inserts. The headphone box presentation was enhanced by using the EVA foam to elevate the product and be flush with the top edge of the box.

Packaging Substrate / Materials:

• Paper wrapped box - 1200 gsm grey board with dull finish flexo print and blind spot UV
• Internal screen printed acrylic sheet
• Die-cut black EVA foam
• Custom printed and die-cut corrugated shipper box to protect the internal box


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Goal Zero | Retail Packaging Design | Packaging Manufacturing

goal zero custom packaging


Our USA design team is ready for your custom packaging project!


Goal Zero Packaging | Case Study

Goal Zero is the industry leader in the emerging portable solar power market. As an exploding start up, Goal Zero needed finished, retail-ready packaging that was up to par with their cutting edge products. They came to Process for support in design collaboration, feasibility of design, testing, and providing full packaging manufacturing.


Goal Zero required packaging that would accommodate a product line with a wide range of purchase price points. They were also concerned about damaged packaging and theft. While addressing these needs, Process provided Goal Zero with packaging that would also create a unique and personal customer experience, at both the retail and post-purchase levels. The packaging also helped consumers become accustomed to the new brand, and provide them with a specific level of education about the products in order to adequately support them in their purchase.


After extensive product packaging testing, Process designed a handmade box with a magnetic flap that revealed the product, while concealing the cords and adaptors for each product.

Goal Zero Retail Packaging Design Materials:

  • Dull coated paper laminated over board
  • 4/4 color with spot UV for additional detail.
  • The outside cover overhangs the interior box to emphasize a book like appearance.
  • An embroidered fabric pull tab on the bottom gives attention to the small detail. This gives the consumers cues to access the product.
  • The retractable metal hang tab allows the package to be hung or stacked for display.
  • The packaging feels hefty and significant, like a gift or coffee table book, the customer experience is enhanced both in retail and post-purchase settings.
  • The product is fully enclosed and provides additional structure, the issues of theft and damages is resolved in the new custom packaging.
  • Interior structures included using a custom molded PET cavity insertion and uniquely designed product suspension.
  • The flap also added additional room for education through a carefully produced system of iconography and typography.

The Result

The end result of this project landed Goal Zero with a cohesive brand across multiple platforms. The packaging system and style guide of rules now are now in place. This allows the packaging to maintain consistency when new products are added to the line.

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Raw Material Packaging Makes a Difference with Marley

Marley is a brand and an icon steeped in history. When it came to developing packaging for their signature line of audio products it was essential that the packaging reflected the brand ethos using raw and natural materials. However, with that comes the challenge and complications of manufacturing eco friendly substrates at a high quality production level.

Raw material goods can be costly and require quality control procedures that understand all plausibility of challenges. The right overseas team, supply chain, paired with the right manufacturing support was key to successfully execute the final manufacturing. This also ensured that the brands eco integrity was upheld while delivering packaging that was at the standard required for large retailers around the globe.

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