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Case Study : Custom Pump Bottle to Solve Leakage Problem

  • Brand Stories & Case Studies
Posted by PauPack OnMar 27 2025

Context


A European and American skincare brand faced frequent issues with leakage and poor pump head rebound performance when using standard market pumps. This resulted in increased return rates and negatively affected product sales and brand reputation. The client was seeking a solution to resolve these issues and improve the overall user experience.

Challenge


The challenge was to design a pump head solution that would prevent leakage while ensuring smooth rebound functionality. The client required a pump that would improve sealing performance and user experience, particularly for frequently used skincare products. Additionally, the design needed to be durable enough for long-term use without compromising quality.

Result


After implementing PauPack’s optimized design, customer satisfaction improved significantly. The new pump head design addressed the leakage and rebound issues, and the return rate dropped by 70%. The client expressed great satisfaction with the solution, resulting in a contract for the development of packaging for the next season's new products. This collaboration not only improved sales but also enhanced the client's brand image.

How We Do It


At PauPack, we conducted a thorough analysis of the client’s needs and redesigned the bottle neck structure and pump head sealing ring. We selected a more elastic inner spring to improve the pump’s sealing performance and rebound function. To ensure optimal performance, we conducted rigorous quality tests at every stage of production. Through these structural and material improvements, we successfully resolved the leakage issue and enhanced the product's overall user experience. This solution not only met the client’s requirements but also resulted in increased customer satisfaction and fewer after-sales issues.

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