Transparency and Flexibility for a Growing B Corp Brand
How Knockout's 100% North American sourcing cut Upfront Cosmetics' lead times and shipping costs by 20 percent, with full supply chain transparency.
- Client
- Upfront Cosmetics
- Industry
- Clean cosmetics
- Packaging Type
- Custom retail cartons (secondary packaging)
- Key Requirements
- Full supply chain transparency, consistent color, flexible order quantities
- Manufacturing Region
- 100% North America
- Outcome
- A 20% reduction in lead time and shipping costs, with recyclable cartons
Upfront Cosmetics
Upfront Cosmetics is a growing B Corp specializing in nutrient-rich shampoo and conditioner bars. Each bar typically saves three plastic bottles from entering recycling streams, and all products are vegan, Leaping Bunny certified, and made in-house.
Upfront takes pride in knowing where every ingredient comes from, and prides itself on sourcing the best possible ingredients, a value they wanted extended to their packaging too.
Learn more about Upfront Cosmetics →
Inconsistent, Untraceable Packaging Was Putting Deals at Risk
Upfront had previously engaged other packaging companies but were disappointed by variations in color and print consistency batch to batch, plus a lack of transparency about where the packaging was really being sourced from overseas. With long lead times, rigid ordering restrictions, and national retailer deals on the line, Upfront needed a change fast, without facing prohibitive switching costs.
- Inconsistent color and print quality from batch to batch
- A lack of transparency into overseas packaging sourcing
- Long lead times and rigid minimum order restrictions
- A need to switch suppliers quickly without high switching costs
100% North American Sourcing, Full Transparency
Knockout's 100% North American sourcing and manufacturing gave Upfront full transparency and quick lead times, using FSC-certified paper for sustainably harvested materials. Digital print avoided the high switching costs of traditional plates and gave Upfront flexibility around order quantities, while hard copy print proofing let the team physically verify color and quality before production.
- 100% North American sourcing for full supply chain transparency
- FSC-certified paper, sustainably harvested and managed
- Digital print to avoid high switching costs
- Hard copy print proofing for quality verification
A 20% Faster, Fully Recyclable Packaging Program
Knockout's process delivered a 20% reduction in lead time and shipping costs, with reorders now averaging a 2-week production lead time. Upfront can easily add or remove SKUs and vary order quantities per SKU, and their packaging is now fully recyclable after removing a plastic matte lamination they hadn't known was there.
- A 20% reduction in lead time and shipping costs
- A 2-week average production lead time on reorders
- Flexible SKU and order-quantity management
- Fully recyclable cartons after removing plastic lamination
Common questions about this project
What does 100% North American sourcing mean for packaging lead times? +
Sourcing and manufacturing paperboard and printing entirely within North America removes the shipping delays and customs steps involved in importing packaging from overseas suppliers.
Why does digital print reduce switching costs for a growing brand? +
Digital print does not require the printing plates that offset printing does, so a brand can update designs or run smaller quantities without paying setup costs for new plates every time.
What is matte lamination, and why might a brand want to remove it? +
Matte lamination is a thin plastic film applied over paperboard for a soft-touch finish. Removing it in favor of an uncoated, textured paper stock can make the carton fully recyclable.
How does hard copy print proofing improve packaging quality control? +
A physical print proof lets a brand check color accuracy, print quality, and paper feel in person before a full production run, catching issues that a digital file preview cannot show.
What packaging changes come with earning B Corp certification? +
Brands earning B Corp certification often update their packaging graphics to reflect the new certification, which a flexible digital print process can accommodate without a full packaging redesign.
