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Premium packaging development & production doesn’t have to be expensive

In addition to providing multiple materials and executing production for Fitbit’s high-end product package, Zenpack handled the package kitting service with more than six different materials, reducing costs and sending the product to market faster.

The Problem

Silicon Valley wearable technology innovator Fitbit asked Zenpack, a premium packaging company, to create and produce a high-end 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, and additional accessories, all within budget.

The Outcome

Zenpack took a holistic approach to choosing the materials: Each element had to work in harmony with the others so that the final package was secure with a uniform, premium look. By setting up the production line, Zenpack helped Fitbit with kitting all of 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 resulting in a premium packaging solution. It again shows that finding the right packaging manufacturer is of the utmost importance for every business.

Fitbit premium packaging design and production


Given the diverse materials, the biggest challenge was creating a cohesive, high-end package. Zenpack produced 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 reduce kitting delivery costs as well.

Package designed for Fitbit USB Cable
Fitbit smartwatch being placed in the packaging


After several rounds of evaluation and testing with the Fitbit team, Zenpack crafted a 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. Inside the box, the acrylic cover elevates the display of the smartwatch and creates a jewelry-like visual effect. The injection-molded plastic holder in the middle of the box secures the smartwatch firmly in place. To ensure the product would display well in retail, Zenpack sourced a strong and durable rope with a base that securely connects inside the box with an invisible attachment.

Zenpack’s strong logistics 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. The final result was a high-quality consumer electronics packaging design.

Different parts of the Fitbit packaging manufactured by Zenpack
Premium cardboard packaging solutions
Several details of the package designed for Fitbit


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 and sampling support helped Fitbit develop the packaging according to their exacting standards. Zenpack’s fully integrated production support saved package kitting and shipping costs, ultimately helping Fitbit launch Surge on time and on budget.

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