ZOLL Itamar
Medical Toolkit
“Important materials enclosed. Do not discard this box.”
The brief
ZOLL Itamar is the sleep-diagnostics arm of ZOLL Medical, the company behind WatchPAT, an FDA-cleared home sleep apnea test that lets patients screen for sleep apnea in their own bed instead of a lab. Its WatchPAT Solutions program gives a clinic everything it needs to run home testing, and all of that arrives in one box that sits on the practice counter and gets reached for again and again.
That is the job the packaging had to do. ZOLL Itamar wanted a “Practice and Patient Material Toolkit” that felt premium enough to represent a medical brand, sturdy enough to be reused, and practical enough to carry: a box a clinic would keep on the desk rather than flatten and recycle. The brief was specific, a corrugated box with a carry handle and a magnetic-close lid, in the WatchPAT blue, printed with the line “important materials enclosed, do not discard this box.”
The issues we solved
A rigid magnetic box hit the premium brief but blew the budget.
We built the same magnetic-close, handled format in printed corrugated, so it keeps the high-end feel at a fraction of the rigid-box unit cost.
Rigid boxes ship pre-formed, so freight and storage cost a fortune at volume.
Our corrugated construction ships and stores flat, then folds up in seconds, cutting shipping and warehousing on every unit.
The toolkit had to be carried and reused, not binned after one open.
We engineered a die-cut fold-out handle and an inside magnet strip, so the box travels like a case and recloses cleanly every time.
Dieline & structure
Structure. The toolkit is a printed corrugated case, 18.5 by 12.4 by 2.5 inches, with a lid that closes onto a hidden magnet strip and a die-cut slot that folds out into a rigid carry handle. It behaves like a briefcase, opens flat to a printed inside lid and a clean tray, and is built on the same custom mailer box engineering we use for shipping-first brands, scaled up here for a reusable kit.
Why corrugated, not rigid. A rigid magnetic box would have met the look, but it ships pre-assembled and prices like a gift box. Corrugated gives the same magnetic-close, handled experience while shipping flat, so ZOLL Itamar gets the premium feel without the rigid-box cost or freight. Our packaging materials guide explains how flute profile and board choice change both cost and protection.
Designing the toolkit
With the structure solved, the print had to carry a medical brand cleanly. The outside runs WatchPAT blue with the ZOLL Itamar logo on the spine and a soft grey WatchPAT Solutions graphic across the lid, finished matte so it reads clinical, not loud. A dedicated panel says “important materials enclosed, do not discard this box,” which turns the packaging itself into a reason to keep it.
Open it and the inside lid speaks to the practice: “We’re proud to support your practice with WatchPAT Solutions,” with “for your practice” and “for your patients” anchoring the two audiences the kit serves. Every colour and panel was proofed before the run, so the case that shipped matched the 3D mockup ZOLL Itamar signed off.
Production & unboxing
“A rigid-box unboxing, engineered in corrugated, handled, magnet-close, and shipped flat.”
The result is a single corrugated case that looks and behaves like a rigid magnetic box: a handled, magnet-close toolkit a clinic keeps and carries, but one that ships and stores flat and costs a fraction of rigid to produce. From dieline to press proof, Packlic handled the whole journey, structure, artwork, 3D mockup and production. If you need premium, reusable packaging without the rigid-box price, you can start your own project with a free 3D mockup and a real quote in 24 hours.
Let’s build your unboxing.
Low minimums, a free 3D mockup in about an hour, and a real quote in 24 hours.
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