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Cut the complexity — 57% off every unit. — PetraSpark case study

Cut the complexity — 57% off every unit.

Nasal Strip CartonsDesign SimplificationFolding Carton
Packaging Types
−57%Per-unit packaging cost
$0.30Per unit, down from $0.70
The Challenge

A complex design built to justify the bill.

Respire was paying $0.70 a unit for a packaging and design system that was far more complex than it needed to be. The complexity wasn’t serving the brand — it was there to justify a higher packing fee. Respire was paying a premium for engineering that added cost without adding value.

The Solution

We simplified what didn’t need to be complex.

PetraSpark stripped the packaging back to what actually mattered. We removed the unnecessary structural and design complexity, kept every bit of the shelf impact and brand identity, and re-engineered the carton for efficient, factory-direct production — bringing the per-unit cost down to $0.30.

Brands that made the switch.

“We were paying $5 a unit and never thought to question it. Petra Spark re-engineered the whole carton, got us down to $2.72, and shrank the box so our shipping dropped too. The packaging actually looks better than before, and the savings land on every single unit.”

Ramon Van Meer

Ramon Van Meer

CEO, Afina

“Petra Spark completely transformed how we show up at retail. Our Target end-caps now stop people mid-aisle. Sell-through is stronger, production costs are leaner — I wish we’d done this sooner.”

Mursal Khedri

Mursal Khedri

CEO, House of Party

“Packaging is brand for us — and Petra Spark got that immediately. The display shelves and gift formats they built elevated our perceived value overnight. Our gifting sets haven’t had a slow season since.”

Geoff Bekavac

Geoff Bekavac

CEO, Everymood

“Packaging is the most overlooked cost in CPG, and honestly one of the easiest to fix. PetraSpark took a real chunk out of our COGS and we never gave up an ounce of quality to get there. I just wish we’d looked at it sooner.”

Roman Khan

Roman Khan

Founder of Peak21

The Results

Where they are now.

Per-unit packaging cost fell 57% — from $0.70 to $0.30 — with no loss in shelf presence, perceived quality, or brand consistency. Respire now pays for packaging that works for the brand, not for complexity that only ever worked for the supplier.

Cut the complexity — 57% off every unit. results

Next Case Study

From $1.00 to $0.85 a unit — zero compromise.

PetraSpark trimmed Nancy’s per-unit cost from $1.00 to $0.85 — same discretion, same quality, a lower cost on every unit.

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