Custom Packaging Case Studies

See how UKPACK turns packaging briefs into production-ready solutions. Our projects cover airless bottles, cosmetic jars, pumps, refillable packaging, and custom dispensing systems developed for real customer applications.

Each case study shows the customer’s requirements, the solution we developed, and the decisions behind structure, materials, decoration, testing, and production. For projects that require a new structure or packaging concept, explore our custom cosmetic packaging design services.

Packaging Projects We’ve Delivered

Explore packaging projects developed for different products, formulas, and market requirements. From custom structures and refillable systems to dispensing solutions and surface decoration, each case shows how a packaging concept was developed and prepared for production.

custom 300ml big airless pump bottle for Little Urchin - 12

Custom 300ml Big Airless Pump Bottle for Little Urchin

A family-size 300 ml airless pump bottle engineered for Little Urchin’s clear zinc kids sunscreen – protected, easy to pump, and ready for everyday beach and backyard use.

custom 50ml refillable airless pump jar for clae - 2

Custom 50ml Refillable Airless Pump Jar for Clae

A compact 50 ml refillable airless jar that keeps Clae’s Super Tallow balm air-tight and hygienic, with a matte brown finish and easy swap-in replacement cartridge.

mono-material lotion pump and bottle for Hemp Worx body wash and lotion - 2

Mono-Material Lotion Pump & Bottle for Hemp Worx Body Wash and Lotion

A mono-material PP pump and bottle that gives Hemp Worx body wash and lotion a smooth, leak-resistant dispense and a more recyclable, full-PP pack.

custom squeezable powder brush bottle for sweeq

Custom Squeezable Powder Brush Bottle for Sweeq

A private-mold HDPE squeezable powder bottle with a built-in soft brush, developed for Sweeq’s all-natural beach sand remover. Family-friendly dosing, clean application, and a pack structure made only for their brand.

weightless wonder serum foundation - the beauty crop

Custom 25ml EVOH Tottle Bottle for The Beauty Crop

A private-mold 25 ml HDPE/EVOH tottle with embossed side logos, soft-touch finish and an electroplated cap, created for The Beauty Crop’s Weightless Wonder Serum Foundation to deliver barrier protection in a lightweight, travel-friendly pack.

fabbri syrup pumps square and round head - 111

Custom 10ml Syrup Pump for Fabbri

UKPACK developed a branded 10 ml syrup pump for Fabbri Mixybar syrups, combining reliable dosing, food-contact certifications and a comfortable round head design that fits their existing bottles.

custom refillable cosmetic jar for The Beauty Crop Vitamin Babe - 1

Custom Refillable Cosmetic Jar for The Beauty Crop

A custom PP refillable jar based on UKC56, developed for The Beauty Crop’s Vitamin Babe Brightening Cleansing Balm. Built with Pantone color matching and silk-screen printing for a consistent, premium look. Finished with an embossed logo spatula to reinforce branding at every use.

custom refillable toner pad jar for FILLUP - 123

Custom Refillable Toner Pad Jar for FILLUP

UKPACK customized a refillable toner pad jar for FILLUP, upgrading daily use with lid stored tweezers for cleaner pad pickup. Screen printing on both the outer jar and the refill insert keeps branding consistent even after refills.

wotnot custom refillable roll-on applicator for sunscreen - 2

Custom Refillable Sunscreen Roll-On Applicator for Wotnot

UKPACK developed a custom refillable roll-on applicator for Wotnot, designed to work with its Natural Zinc Sunscreen tube and make daily sun protection more portable, reusable, and convenient for on-the-go use.

befe 240g hair mask jar - 3

Befe Hair Mask Jar Packaging Upgrade

UKPACK helped Befe develop its 240g hair mask jar in two stages, first using our UKC41 cosmetic jar platform for fast production, then upgrading the product with a custom refillable jar mold and replaceable inner system.

250ml pp jar for iota superchili body mask - 2

Custom Glossy PP Jar for iota Superchili Body Mask

UKPACK customized its UKC15 250ml double-wall PP jar into a glossy white body mask jar for iota. The project focused on surface finish customization, wide-mouth usability, and precise screen printing for a clean minimalist packaging look.

custom 150ml pet press bottle for horace - 1

Custom 150ml PET Press Bottle for Horace

UKPACK developed a custom 150ml PET press bottle for Horace’s Skin-Perfecting Exfoliating Solution, matching the brand’s required capacity with a compatible press pump system for controlled skincare application.

custom duo-mix airless bottle for malevich - 2

Custom Duo-Mix Airless Bottle for Malevich

UKPACK supplied the UKA84 refillable dual chamber duo-mix airless bottle for Malevich’s Magic Drops Chromatique C vitamin C serum, supporting separated ingredient storage, in-bottle activation, and controlled airless dispensing.

custom pp cosmetic cream jar for peach up - 2

Custom PP Cosmetic Cream Jar for Peach Up

UKPACK customized its UKC41 PP cosmetic cream jar with vibrant colors and silk screen printing for Peach Up’s BOOM BOOM UP, SUGAR UP, and FIT UP body care products.

8ml syrup pump for origin tea - 2

8ml Syrup Pump for Origin Tea

UKPACK supplied a 28/410 8ml syrup pump for ORIGIN TEA’s 750ml iced tea and flavoured syrup bottles, helping improve dosing accuracy and cleaner drink preparation.

Nimue plump and firm contour gel for eyes and lips - 2

Eye Cream Bottle with Metal Cooling Tip for Nimue

A customized UKJT007 eye cream bottle for Nimue’s eye and lip contour gel, featuring a slim treatment-style body, clear cap, and metal cooling applicator.

black radiance setting spray - 2

Custom Setting Spray Bottle for Black Radiance

A customized 60ml PET spray bottle for Black Radiance’s setting spray collection, designed with a black body, fine mist sprayer, and variant-specific decoration.

custom airless pump bottles for m. skincare - 1

Custom Airless Pump Bottle for M. Skin Care

A customized UKA06 airless pump bottle solution for M. Skin Care’s men’s skincare serum, lotion, and gel product line.

custom eye cream bottle with metal applicator for dr.wu - 2

Custom Eye Cream Bottle with Metal Applicator for DR.WU

A customized 15ml UKJT009 eye cream bottle solution with a curved metal applicator, designed for DR.WU’s targeted anti-aging eye cream.

custom spray bottle and airless pump bottle for lyma - 2

Custom Spray Bottle and Airless Pump Bottle for LYMA

A customized spray bottle and airless pump bottle solution designed for LYMA’s two-step Oxygen Mist & Glide skincare routine.

custom powder spray bottle for maison lavande - 11

Custom Powder Spray Bottle for Maison Lavande

UKPACK’s UKP10 fine mist powder spray bottle helped Maison Lavande upgrade its Pure Lavender scented powder into a compact, non-aerosol pump format for cleaner and more controlled application.

custom cosmetic tube packaging for step by medica - 2

Custom Cosmetic Tube Packaging for Step by Medica

UKPACK cosmetic tube packaging helped Step by Medica present its 120g moisturizing cream in a clean, practical, and professional skincare format suitable for daily barrier-support care.

custom sunscreen stick packaging for acure - 2

Custom Sunscreen Stick Packaging for Acure

UKPACK stick packaging helped Acure present its 15g sunscreen stick in a clean, portable, and practical format for daily sun protection and on-the-go use.

custom 500ml airless pump bottle for zuche - 2

Custom 500ml Airless Pump Bottle for Zuche

UKPACK provided a UKA22 500ml airless pump bottle for Zuche’s skincare range, ensuring hygienic and controlled dispensing for high-viscosity formulations.

we-are-feel-good-inc-bubs-100ml-mono-pp-airless-bottle-2

100ml Mono PP Airless Bottle for We Are Feel Good Inc.

UKPACK supplied the UKA19 100ml mono PP airless bottle for Bubs Baby Mineral Sunscreen SPF50+, combining controlled dispensing with a custom pastel finish.

we-are-feel-good-inc-groms-100ml-roll-on-bottle - 2

100ml Roll-On Bottle for We Are Feel Good Inc.

UKPACK supplied the UKROB001 100ml roll-on bottle for Groms Kids Sunscreen Lotion SPF50+, providing a convenient direct application format for family outdoor use.

eco-tan-glory-cream-1-7-fl-oz-airless-jar-2

Airless Jar for Eco Tan Glory Cream

UKPACK supplied the UKAJ013 1.7 fl oz airless jar for Eco Tan Glory Cream, combining controlled dispensing with a refined jar-style presentation.

barriers-the-lip-balm-10ml-lip-balm-tube - 2

10ml Lip Balm Tube for Barriers

UKPACK supplied the UKLB001 10ml PE lip balm tube for Barriers The Lip Balm, combining squeeze dispensing with a smooth ceramic applicator and a refined metallic presentation.

custom-15ml-eye-cream-bottle-for-new-angance-2

15ml Eye Cream Bottle for New Angance

UKPACK supplied the UKJT009 15ml eye cream bottle for New Angance, featuring a curved metal applicator for precise application and a refreshing cool-touch experience.

wellu-larens-beauty-eye-compress-dual-chamber-jar-2

50ml+50ml Dual Chamber Jar for WellU

UKPACK supplied the UKC35 50ml+50ml dual chamber cosmetic jar for WellU’s Larens Beauty Eye Compress, combining two compartments in one premium skincare package.

custom-30ml-dropper-bottle-for-giant-biogene-2

30ml Dropper Bottle for Giant Biogene

UKPACK supplied a custom 30ml dropper bottle for Giant Biogene’s COLLGENE Safety Repair Pre-Essence, combining controlled dispensing with a clean, treatment-oriented design.

Ready to Bring Your Next Packaging Project to Life

Tell us what you want to achieve. Our team will help you choose the right structure, engineer the tooling, validate performance, and scale up for production.

Questions About Custom Packaging Projects

Yes. We can start from a product brief, reference packaging, sketch, 3D concept, or existing structure. Our team evaluates the dispensing system, materials, dimensions, decoration, tooling requirements, and production feasibility before moving into sampling and validation.
No. Many projects can be developed using an existing bottle, jar, pump, or closure with customized colors, decoration, components, and branding. New tooling is generally considered when the required structure, dimensions, dispensing function, or appearance cannot be achieved with an existing platform.
Yes. Existing packaging can often be adapted through component changes, color matching, surface finishes, printing, dispensing options, or structural adjustments. We first review the original pack and identify which elements can be retained and which need redevelopment.
Testing depends on the packaging structure and formula requirements. Typical validation can include leakage, dispensing performance, assembly, dimensional checks, decoration adhesion, compatibility, and transportation-related tests before the final production specification is approved.
Yes. UKPACK supports projects from packaging development and component selection through sampling, testing, tooling, decoration, assembly, and mass production. Keeping these stages connected helps reduce compatibility and production issues during scale-up.
Start with the product type, formula, target capacity, dispensing method, preferred material, expected decoration, estimated order quantity, and any reference packaging or drawings you already have. The more complete the brief is, the easier it is to evaluate suitable structures and development requirements.
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