For Phonak, a brand of the Sonova Group, we developed highly compact carton-based individual packs for hearing aid accessories. As part of the EasyGuard™ Starter Kit, they replace a previous plastic packaging solution and combine strong packaging functionality with machine processability in a minimal format.

Compact individual packs with high functionality

The key challenge lay in the compact format of the individual packs. The dimensions were predefined and close to the technical minimum for machine processing. Nevertheless, essential packaging features had to be reliably integrated: Euro hole hanger, front opening with tamper-evident function, reclosure, secure holding points, as well as the required pre-creases and glue lines for machine erection.

The solution demonstrates how high packaging functionality can be achieved within a minimal space when structural design, processing requirements and visual design are precisely aligned.

 

Precise construction for machine processing

The smaller the packaging format, the more precisely construction, material behaviour and production process need to interact. For the Phonak EasyGuard™ individual packs, this precision was essential to ensure that the packs could be reliably erected, filled and further processed.

The construction combines product protection, ease of handling and industrial process reliability in a compact format. The result is a carton packaging solution that is functional while also meeting the requirements of efficient series production.

 

Clear design for a sensitive product environment

The reduced design supports Phonak’s premium brand presence. The bright, clean visual language provides orientation and conveys precision, quality and trust. Despite the compact format, the packaging appears clear, structured and visually precise.

This makes the packaging well suited to a sensitive product environment where functionality, reliability and a clear visual identity are particularly important.

 

EasyGuard™ Starter Kit as retail packaging

The individual packs are brought together securely and clearly within the EasyGuard™ Starter Kit. The carton-based retail packaging also replaces a previous plastic solution and consists of a base, integrated insert and sleeve.

This extends the transition from plastic to carton across the entire packaging system. At the same time, the EasyGuard™ Starter Kit expands the solution into a well-designed packaging system with secure product positioning, easy handling in retail and a high-quality presentation.