Solving a Recurring Color-Matching Problem for a Mineral Sunscreen Brand
How Knockout delivered guaranteed Pantone-accurate cartons for Brush On Block, run after run, manufactured close to the brand's own production facility.
- Client
- Brush On Block
- Industry
- Mineral sun care
- Packaging Type
- Retail unit cartons (secondary packaging)
- Key Requirements
- Guaranteed color consistency across every production run, short lead times
- Manufacturing Region
- Close to Brush On Block's own manufacturing facility
- Outcome
- Consistent, accurately color-matched cartons on every reorder
Brush On Block
Brush On Block makes reef-friendly mineral sunscreens, free of chemical UV filters and formulated to be PETA-certified cruelty-free and vegan. As a women-led business, the brand keeps ingredients and packaging under constant review, operating at the intersection of human safety, environmental responsibility, and everyday functionality.
Their customers read labels closely, on the product and on the box, which made packaging color accuracy more than a cosmetic detail. It's part of how the brand keeps their trust.
Learn more about Brush On Block →
When Color Consistency Breaks, So Does the Brand
Brush On Block had grown frustrated with a recurring problem: color matching issues meant their signature packaging colors weren't showing up the way they should, run after run. They needed a partner who could guarantee consistency, work with short lead times, and manufacture close to where their products are actually produced.
- Guaranteed color consistency across every production run
- A recurring color-matching problem that needed a permanent fix
- Short lead times on reorders
- Manufacturing located close to their own production facility
Pantone Solid Coated, Locked In From the Start
Knockout identified the specific areas of the production process where color was drifting between runs, then standardized on Pantone Solid Coated matching to remove the guesswork. That standard, paired with more sustainable material choices in the design itself, gave Brush On Block a repeatable process instead of a run-by-run gamble.
- Identified where color consistency was breaking down between runs
- Standardized on Pantone Solid Coated color matching
- Incorporated more sustainable elements into the packaging design
- Built a repeatable process for future reorders
A Brand Represented Exactly as Envisioned
With Pantone Solid Coated matching now locked into the production process, Brush On Block can trust that their brand shows up on shelf exactly the way they envision it, order after order. The consistency issue that started the project is resolved, and the packaging now carries more sustainable elements without sacrificing the brand's signature look.
- Consistent, accurate color matching on every production run
- A repeatable process instead of a recurring problem
- More sustainable packaging elements built into the design
- Faster turnaround from a manufacturing partner close to production
Common questions about this project
Why does packaging color drift between production runs? +
Color can shift between runs when a brand relies on a printer's process-color build (CMYK) rather than a fixed, pre-mixed ink standard. Small variations in press calibration, paper stock, or ink batches then show up as visible color differences from one order to the next.
What is Pantone Solid Coated matching, and why does it fix color consistency? +
Pantone Solid Coated is a standardized, pre-mixed ink system rather than a process-color build. Specifying a single Pantone Solid Coated reference gives a printer an exact, repeatable formula to match on every run, which removes the guesswork that causes color drift.
Why is color accuracy especially important for a sunscreen brand? +
Sun care shoppers often rely on packaging color to quickly tell products and shades apart on a shelf or in a bag. Inconsistent color between production runs can create confusion at the point of purchase and undercut the polished look a brand has built.
Why choose a manufacturing partner close to your own facility? +
Manufacturing near a brand's own production site shortens lead times and simplifies quality oversight on reorders. It also makes it easier to troubleshoot issues like color drift quickly, rather than waiting on a distant supplier.
How does Knockout help brands fix recurring packaging quality issues? +
Knockout starts by identifying exactly where a production process is breaking down, then standardizes materials, color systems, and supplier relationships to turn a recurring problem into a repeatable, reliable process.
