Secondary packaging is where brand identity meets real-world performance. It protects your product through transit, tells your story on shelf, and increasingly signals your values to a customer base that pays attention to how things are made.
Knockout manufactures secondary packaging across North America using FSC/SFI-certified paperboard, low-VOC inks, and water-based coatings. Every component is produced as close as possible to your delivery location to keep lead times short and carbon footprint low.
The workhorse of beauty and wellness packaging. Folding cartons are custom-designed to fit your primary packaging, communicate regulatory information, and create a branded moment at shelf or in the mailbox.
Materials: FSC/SFI-certified paperboard, recycled-content board, specialty stocks. All raw materials sourced within North America.
Print & Finish: Offset lithography, low-VOC and vegetable-based inks, water-based coatings and varnishes, spot UV, foil stamping, embossing, debossing, soft-touch coatings, windowing.
Customization: Custom structural design, inserts and fitments, Pantone colour matching, regulatory panel layout, barcoding and serialization.
Best for: Unit cartons for skincare, cosmetics, haircare, wellness supplements, fragrance, and lifestyle products
Luxury rigid boxes for kits, seasonal collections, gift sets, and elevated unboxing experiences. Knockout designs custom inserts that keep products secure during transit while reducing breakage and operational waste. Sustainable material options are available without compromising the premium feel.
Features: Magnetic closures, ribbon pulls, custom foam and paperboard inserts, modular tray systems, wrap-around printing, specialty papers and textures
Sustainability note: Knockout has developed glueless tray systems and modular designs that deliver a rigid-box experience using folding carton construction, significantly reducing material waste and improving recyclability. See the Aethereal case study for an example.
Best for: Holiday kits, gift sets, product launch boxes, subscription boxes, premium retail presentation
Lightweight, protective tube packaging for daily-use and travel-friendly products. Knockout offers multiple tube constructions to match formulation sensitivity, sustainability goals, and branding requirements.
PCR Tubes: Made with post-consumer recycled plastic. A practical step toward reducing virgin plastic usage while maintaining familiar tube performance.
Mono-Material Tubes: Single-material construction designed for improved recyclability. Eliminates the multi-layer barrier that makes traditional tubes difficult to recycle.
COEX Barrier Tubes: Multi-layer co-extruded construction for formulations that require enhanced protection against oxygen, moisture, or light. Ideal for active ingredients, retinoids, and vitamin C products.
Aluminium Tubes: Fully recyclable, impermeable, and widely used in premium skincare and pharmaceutical applications. Excellent barrier properties and a distinctive tactile quality.
Customization: Custom orifice styles (standard, slant, needle-tip), flip-top and screw-cap closures, offset and screen print decoration, embossing, hot stamping.
Best for: Moisturizers, sunscreens, hand creams, serums, toothpaste, ointments, primers
Best for: Moisturizers, sunscreens, hand creams, serums, toothpaste, ointments, primers
Lightweight shipping mailers for smaller DTC orders and individual product shipments. Choose between all-paper padded formats for fully recyclable solutions or bubble-lined mailers when additional cushioning is required.
Options: Paper-padded mailers (curbside recyclable), bubble mailers (added cushion), custom sizes and branding
Best for: Single-item DTC orders, sample mailings, lightweight product shipments
Custom labels for branding, regulatory compliance, and inventory management. Knockout offers both short-run digital and high-volume flexo label production with fast North American turnaround.
Formats: Pressure-sensitive labels, shrink sleeves, wrap-around labels, tamper-evident seals
Print methods: Digital (short-run, fast turnaround), flexo (high-volume, cost-efficient), foil and specialty finishes
Sustainability note: Where possible, we recommend recyclable pressure-sensitive labels with water-soluble adhesives that improve release during recycling and support cleaner material recovery.
Best for: Primary container labelling, promotional stickers, compliance labels, serialization, inventory tracking
Whether you need a simple unit carton or a fully custom gift box with modular inserts, Knockout has the structural design expertise and manufacturing relationships to make it happen. Reach out to start the conversation.
