Hyperice Evolves Global Packaging Strategy to Support New Product Launches | Life Sciences
1/13/2026
RRD Asia’s innovative packaging production solutions lead to systemic improvements and cost savings
CHALLENGE
Hyperice, a global leader in recovery and performance technology, is powered by a team of forward-thinking innovators passionate about helping “everyone on Earth move better, live better, and be better.” Recognized worldwide for setting new standards in warm-up and recovery solutions, Hyperice's products have earned multiple prestigious industry honors. The company has also been named to Fast Company’s list of the World’s Most Innovative Companies and the Inc. 5000 list of fastest-growing private companies in the U.S.
As Hyperice continued expanding their portfolio of wellness devices, they recognized the critical role packaging plays in delivering a consistent, high-quality brand experience. Hyperice desired packaging that reflected the quality of their technology, delivered consistent performance across regions, and supported efficient new product introductions (NPIs) worldwide. In addition, Hyperice sought:
- Cost reductions to streamline packaging procurement and reduce obsolescence
- Greater flexibility in graphics, materials, and other specifications — without compromising quality
- Improved dependability and delivery through more reliable order management, warehousing, fulfillment, and adaptable arrangements for their contract manufacturers
- Faster speed to market through an efficient NPI process that could be globally managed with various stakeholders and partners
SOLUTION
To address these challenges, RRD established a global team dedicated to supporting Hyperice’s expanding packaging program and coordinating directly with their contract manufacturers. RRD team members from the U.S. and Asia collaborated closely with Hyperice to focus on strategy and alignment, develop NPIs, manage orders, forecast demand, and support artwork and production. RRD’s solution centered on four core areas:
- Product introductions: To facilitate quick decision-making and support the seamless introduction and progression of product launches, the RRD global NPI team initiated weekly coordination with key Hyperice stakeholders across multiple U.S. locations, including supply chain, product owners, packaging design engineers, quality, manufacturing, and other departments.
- Quality standards: RRD worked closely with Hyperice’s quality, engineering, and sourcing teams, along with their contract manufacturers, to establish consistent and acceptable quality standards across packaging and labels.
- In-house qualification: RRD supported the testing of multiple EVA liner materials and other packaging components. All testing and qualification work was supported by RRD Asia’s in-house test lab, helping reduce lead times and improve speed to market.
- Sustainable packaging: RRD also reduced Hyperice’s materials footprint by incorporating more sustainable substrates, inks, and other components across current programs and product introductions.
RESULTS
RRD adopted a strategic approach to packaging optimization, cost reduction, and effective account management, successfully meeting Hyperice’s goals of improving operational efficiency and flexibility. This proactive collaboration, combined with innovative packaging production solutions, resulted in significant cost savings, improved production processes, and increased sustainability.
Outcomes of the partnership include:
- Streamlined process: RRD enhanced production efficiency by unifying the sleeve material, surface treatment, and structural specifications of the solid bleached sulfate folding carton box.
- Cost savings: A combination production run was implemented, enabling Hyperice to combine materials and leverage larger minimum order quantities.
- Increased sustainability: The new packaging replaced some plastic usage, reduced overall weight, and led to innovation in materials usage and structural design.
- Improved quality standards: RRD Asia identified the most effective and economical replacement materials to solve quality issues Hyperice faced with their incumbent vendors. This helped prevent staining and elevated the unboxing experience for consumers.
- Strengthened brand stewardship: By leveraging broad capabilities, RRD added meaningful value across different aspects of the brand experience, helping the company maintain a unified presence in every market.
- Optimized demand and supply management: RRD effectively managed stock quantities and delivery schedules, creating a smooth transition and maintaining operational efficiency.
- Program expansion: Together, Hyperice and RRD successfully introduced new products for over 300 packaging, labeling, and commodity items, meeting on-time delivery requirements across eight original equipment manufacturers within just six months.