New product packaging development One packaging partner. Primary and secondary. Zero hand-offs.
Launching a new SKU can be complex, with multiple component vendors, a Gantt chart, and praying the primary and secondary packaging actually fit together. It takes one point of accountability, working alongside your existing team to resolve current issues and head off future ones, and owning the whole package.
Book a consultation →The Knockout 6-step packaging process.
Our simple, proven guide to take packaging from idea to shelf, faster and with fewer surprises.
Discovery We map your product, channels, budget and deadline before choosing any components. 
Design Structure, artwork and dielines are specced together so everything fits your filler. 
Source Vetted factories in North America, Europe and Asia quote to your budget. 
Quality Control Samples and production runs are inspected before anything ships to your door. 
Production One project manager tracks every component to your fill line on schedule. 
Delivery Freight, customs and duties are handled, with components arriving ready to fill. The way most brands source packaging is broken.
Here's what "normal" looks like in 2026:
- One supplier for bottles. A different one for pumps. Another for cartons. A fourth for shippers.
- Four MOQs. Four timelines. Four QC standards. Four different people who don't talk to each other.
- A launch calendar that slips every time one of them quotes a new lead time.
- A pump that doesn't seat in the bottle the closure was specced for. A shipper that fails ISTA because the carton was approved before the secondary spec was locked.
This isn't procurement. It's a relay race with no baton.
Every hand-off between primary and secondary vendors adds risk, time, and margin leakage. We've seen brands lose 6 to 10 weeks on a single launch because the carton supplier was waiting on final bottle dims the bottle supplier hadn't finalized yet.
We run the whole package. On purpose.
Knockout is a North American packaging operations partner that owns the full stack, from the bottle in your consumer's hand to the shipper on the pallet, under one roof, one timeline, one accountable team.
Primary containers, closures, pumps, cartons, inserts, shippers, labels. Specced, sourced, tested, and shipped as a single system.
No more waiting on Vendor B before Vendor C can quote. We sequence the entire build against your launch date, not against four separate lead times.
The same team that signs off on your bottle signs off on the carton it ships in. Drop tests, compatibility tests, ISTA, compliance. All owned, all documented.
When something goes sideways, and on new product launches something always does, there's one phone number. Not four.
Built for the two people holding the bag on launch day.
For emerging and scaling brands
You've validated the product. Your formulator is locked. Your CM is quoting. Now you need packaging that doesn't become the bottleneck that pushes your H2 launch into Q1. We partner with founders, brand ops leads, and product marketing teams who don't have time to run a supplier orchestra, and who've learned the hard way that cheap per-unit pricing on one component can cost you the whole launch window.
For Brands →For contract manufacturers
Your clients want NPD moved faster, MOQs flexed lower, and a packaging partner who shows up as an extension of your team, not a procurement liability you have to babysit. We plug into your operational rhythm. Our spec sheets, sampling protocols, and QC documentation integrate with your existing workflows. Your clients see one seamless program. You spend less time chasing vendors.
For Contract Manufacturers →How we actually get a new product launched.
Five stages. One team. No hand-offs.
01Brief and feasibility
We start with your product, your channel, your launch date, and your budget. We come back with a realistic integrated spec, primary and secondary, with the trade-offs mapped before you commit to a single mould or die.
02Spec and source
We lock the full packaging system against your fill line, your CM's capabilities, and your retail or DTC channel requirements. Every component is specced to work with every other component.
03Sample and validate
Functional samples, compatibility testing, drop and vibration testing (ISTA-ready), regulatory compliance review. You approve what ships, with documentation your retailer, CM, and legal team will all accept.
04Production and run
Coordinated production across primary and secondary components, sequenced so your CM isn't waiting on cartons while bottles sit on a dock. We manage lead times, QC at origin, and inbound logistics as one program.
05Scale and iterate
First run teaches you things no spec document ever will. We stay in the loop, flexing MOQs, refining specs, and supporting reorders as your SKU moves from launch into steady state.
Everything your product needs to get to shelf.
Primary packaging
- Bottles, jars, tubes, pouches. Glass, PET, PCR, PP, aluminium
- Closures, pumps, droppers, sprayers, roll-ons, airless systems
- Decoration: labels, direct print, hot stamp, silk screen, shrink sleeves
- Sustainable formats: PCR resins, mono-material systems, refillable architectures
Secondary packaging
- Folding cartons, rigid boxes, setup boxes, sleeves
- Inserts, trays, dividers, custom-fit to your primary
- Shippers, mailers, e-comm-ready packaging (ISTA 6-Amazon, SIOC)
- Certified sustainable stocks: FSC, SFI, PCR paper, compostable options
Operational support
- Packaging engineering and testing
- Regulatory compliance (FDA, Prop 65, EU, Canada labelling)
- Sample programs and first-article inspection
- Warehousing, kitting, pick-and-pack, and fulfillment coordination
A combined fifty years. Thousands of launches. One thing we don't do: miss.
Combined team experience across beauty, wellness, personal care, and lifestyle brands. We've seen every launch curveball, and built the playbook for it.
Primary and secondary, sourced and managed under one roof, end to end.
Proximity to CMs, fill lines, and distribution. Shorter lead times. Faster iteration. Fewer passport stamps on your packaging.
Engineered for NPD realities: pilot runs, soft launches, line extensions. We scale up with you. We don't force you to scale into us.
Questions we get every week.
We already have a primary packaging vendor. Can you just do our secondary?
Yes. Plenty of our engagements start that way. But here's the honest answer: most brands who come to us for secondary end up consolidating primary too, because once you see what integrated looks like, juggling vendors feels like a choice you're making, not a constraint you're solving.
How low can MOQs actually go?
Lower than you think, and it depends on the component. Folding cartons and labels flex further than glass or custom tooling. On a first call we'll tell you exactly where your MOQs will land for the full system, not just the cheapest component.
Are you a broker or do you manufacture?
We're an operational partner with a vetted network of producers in North America, Europe and Asia, and a full internal engineering, QC, and program management team. You get the selection of a network with the accountability of a single partner.
How does this work with our contract manufacturer?
Cleanly. We've integrated with dozens of CMs across beauty and wellness. We align to their fill line specs, sampling protocols, and production schedules so your CM gets components that work on day one, not after two rounds of rework.
Sustainability: real, or marketing?
Real. PCR resins, FSC/SFI certified papers, mono-material systems, refillable architectures, recyclability engineering. We'll also tell you when a "sustainable" spec doesn't actually improve end-of-life outcomes, because the math matters more than the claim.
How we cut packaging lead times
A vetted network of global manufacturers that deliver faster, not just cheaper.
No more chasing multiple vendors. One brief, one partner, coordinated delivery.
We present clear options quickly, so teams move forward without bottlenecks.
Fewer mistakes means fewer do-overs, which saves weeks.
Where timing matters most, we offer North American runs to keep launches on track.
One partner. One package. One launch on time.
Tell us about the product and let's discuss simple ways we can help shorten your timelines.
Or email info@knockoutpkg.com