Zotos International, a leader in the professional hair care products industry, recently explored new packaging options for Joico VeroChrome™, a popular hair colorant featuring vibrant color results and brilliant conditioning. Diamond Packaging was asked to design and manufacture a carton that would improve filling line efficiencies in their production facility.

The packaging for VeroChrome™ products has always incorporated a natural look, in part to differentiate it from competing products as well as its other product lines. Joico wanted to leverage this identity in any new carton design.

To better understand the customer’s requirements, members of Diamond’s technical team visited Zotos’ fulfillment center to assess the filling equipment and see it run with their current cartons. The inconsistent caliper and texture of the substrate used by another vendor caused the production lines to slow down due to problems related to openability and magazine release.

Diamond solved the problem by designing a carton printed on the reverse side of a special recycled board. The smooth texture of the satin aqueous-coated board enhances the fine line art reproduction and contributes to problem-free operation on the filling lines.

“Efficiencies increased over 100%,” said Michele Rago, Buyer/Planner at Zotos International. “The people that work on the line are ecstatic about the results from making this change.”

Diamond retained the natural look and feel of the popular VeroChrome™ brand, while reducing production costs.