Case Study: Color Street Scales At-Home Nail Kit Fulfillment with Pack-Smart Inc. Automation

Discover how Pack-Smart’s FG-500 automation line quadrupled Color Street’s daily kit output to 400,000 units while slashing labor from over 150 temporary staff to just 20 operators.

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Creator of digitally printed, real-nail polish strips in vibrant patterns, where initial kit assembly relied on 150+ temporary staff, creating bottlenecks.

Overview

As Color Street’s at-home nail kits soared in popularity, its labor-intensive assembly model couldn’t keep pace. Each kit required manual collation of six components, from polish strips to pre-printed envelopes; adding cost and inconsistency. To break free from headcount constraints and support weekly product launches, Color Street tapped Pack-Smart Inc. for a turnkey automation platform.

Challenges

Heavy reliance on temporary staff drove high labor costs and variable quality.

Production couldn’t scale without proportionally more headcount.

Complex, multi-component kits demanded precise manual collation.

Frequent design updates threatened to interrupt operations.

Solution

Pack-Smart Inc. deployed a customized FG-500 pick-and-kit folder-gluer line that automated every assembly step in a single pass.

Redesigned cartons eliminating pre-formed envelopes.

Automated feeding of pre-printed, die-cut blanks.

Inline assembly, folding, gluing, coding, batching and boxing.

Operation by just three staff per line at speeds up to 14,000 kits/hour.

Results

Labor requirements plunged from over 150 staff to just 20 across four lines.

Daily output jumped from 100,000 kits to 400,000 kits.

Design-to-shelf lead time shrank from multi-week bottlenecks to seamless weekly launches.

Machines built in 16 weeks and installed in two.

24/7 operation delivered minimal downtime and consistent quality.

Flexible architecture now supports rapid design changes and new SKUs.

Continuing Partnership

Pack-Smart Inc. continues to refine Color Street’s system with equipment enhancements for new product variations. We provide scheduled onsite maintenance and remote diagnostic support to maximize uptime. Together, we innovate designs to future-proof operations against evolving market demands.

Conclusion

By automating its kit assembly, Color Street transformed a labor-heavy process into a high-speed, scalable operation. This partnership not only met explosive demand but also established a blueprint for global expansion in direct-sales cosmetics.

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