Fitbit

Premium packaging development & production doesn’t have to be expensive
Zenpack provided the multiple materials for Fitbit’s high-end product package and executed production, plus Zenpack provided packaging kitting service with more than six different materials, all working together saved Fitbit from paying extra kitting costs.
The Problem
Silicon Valley wearable technology leader Fitbit asked Zenpack to create and produce a premium package solution for Surge — their high-end product line. Zenpack was tasked with creating a sophisticated packaging design using a wide range of specialized materials including the paper box, acrylic cover, plastic tray, elastic hang loop, etc, all within budget.
The Outcome
Zenpack took a holistic approach to choosing the materials: each element had to work properly with the others so that the final package was both secure, and had a uniform, premium look. By setting up the production line, Zenpack helped Fitbit with kitting all the packaging material together under one roof. That meant when the packages were delivered, Fitbit simply had to insert the product into the ready-made packaging. In the end, this method saved everyone time and money.
Challenges
The biggest challenge was creating a cohesive, high-end package, given the diverse materials. Zenpack created a variety of samples for the client to review before determining the best option. During this process, both materials and structural strength were considered. The size of the package was important too, and the client needed to find a way to help on kitting delivery costs as well.
Solution
After several rounds of evaluation and testing with the Fitbit team, Zenpack came out with an ultimate solution that not only passed the ITSA 3A test, but also merged more than six different materials in one attractive package format. The folded rigid box with a magnetic lock displays both the beautiful pattern and critical copy that the client needed to include. Meanwhile the acrylic cover inside the box elevated the display of the smart watch and create a jewelry-like visual effect. The injection-molded plastic holder in the middle of the box to hold the smart watch securely in place. To ensure the product would display well in retail, Zenpack also sourced a strong and durable rope with a base that securely connected inside the box with an invisible attachment.
Zenpack’s strong logistic team used software to create a cartonization and palletization system for Surge, which maximized space efficiency and resulted in shipping cost savings for the client. Zenpack harnessed local support in the daily sampling process and provided production feedback promptly to ensure on-time delivery with maximum efficiency.
Result
Fitbit is an innovative technology company that has sold millions of smart devices worldwide, and when they needed high-quality packaging for their premium products that would help create cost efficiency, they turned to Zenpack. The local structural engineering & sampling support helped Fitbit develop the packaging properly and Zenpack’s fully integrated production support helped Fitbit save packaging kitting & shipping cost, ultimately helping Fitbit launch Surge on time and on budget.
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