Case studies · Beauty & Skincare
Lumen Skincare — Modular refill system
Lumen wanted to launch a refill-first skincare system — a permanent outer rigid box with swappable inner refill cartons — to reduce customer churn and landfill impact.
64% in 6 months
Refill adoption
−42% per refill cycle
Material reduction
−40%
Cost per refill unit
The challenge
What the brand came in with.
Lumen wanted to launch a refill-first skincare system — a permanent outer rigid box with swappable inner refill cartons — to reduce customer churn and landfill impact.
The solution
What we built together.
We designed a 2-piece rigid outer box with a magnetic closure and a die-cut foam insert that holds up to three refill cartons. Refill cartons are produced in mono-material SBS, sized to the outer box, and printed with minimal graphics. The result: customers keep the outer box for life, and refills cost 40% less than full packaging.
Materials
What it's made of
- ●2mm greyboard
- ●SBS
- ●Die-cut foam
Finishes
How it's finished
- Soft-touch lamination
- Foil stamping
- Spot UV
Production
Step by step.
01
Concept
3D rendering of refill mechanism in 3 days.
02
Sampling
Functional prototype in 14 days.
03
Production
22 business days for full launch run.
Gallery
Selected product photography.
Project FAQ
Questions about this project.
Outer box at premium, refills at standard.
The outer rigid box is priced as a one-time premium. Refill cartons are produced at standard folding-carton pricing — typically 40% less than the original full packaging set.
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