From Subscription Boxes to Merch Drops: Kitting Projects That Build Brands

When most people hear the word kitting, they picture a warehouse worker sliding two SKUs into a poly-bag and calling it a day. But in the hands of a growth-minded brand, kitting is closer to stagecraft than it is to basic fulfillment. A well-built kit can launch a product, fuel an influencer’s unboxing video, or keep subscribers counting the days until the next delivery. At All Points we've seen bundles of coffee and candles drive six-figure Kickstarter campaigns, and we’ve watched a single limited-edition merch drop generate more organic social impressions than a month of paid ads. 

‍

Below, we break down the most creative kitting programs we’ve executed, share best practices for short-run, high-touch projects, and explain how our in-house packing and insert-printing capabilities shave off timelines so your big idea leaves the dock on schedule and in style. 

‍

Creative Kitting in Action: Real Projects from All Points 

KontrolFreek - Gaming Gear, Subscription-Box Precision

KontrolFreek’s controllers and performance thumbsticks are fan favorites, but the brand’s growth hinged on delivering a fresh, perfectly packed kit every month. All Points carved out a dedicated work cell inside its Atlanta facility, complete with color-coded pick carts and line-side quality checks. That single cell now assembles up to 10,000 subscription kits per day, keeping product, swag, and a rotating “mystery item” in perfect order. Since launch, more than 775,000 game-night kits have shipped to fans around the globe, without a single month of backorders. 

Mailchimp: VIP & Holiday Mailers in Under 24 Hours 

When Mailchimp wants its partners and influencers to open a gift that feels as thoughtful as its emails, speed and presentation both matter. The marketing platform turns to All Points for roughly twenty bespoke mailings a year, ranging from a few hundred eco-friendly welcome boxes to a few thousand holiday gift packs. Inserts are printed in-house on recycled stock, tissue is brand-matched, and kits are out the door within twenty-four hours of final approval. It’s proof you can be fast and sustainable at the same time. 

CareCredit: Compliance Rollout on an Industrial Scale 

Re-branding a financial service means every point-of-sale brochure, rate sheet, and training packet must update overnight. CareCredit asked All Points to manage a nationwide refresh that ultimately required 358,000 multi-version kits. Thirteen distinct versions, each with its own mix of manuals, tent cards, and counter mats, were produced at an average clip of 10,000 kits per day. Despite the complexity every box shipped in the correct wave, and the project closed with zero accuracy errors which is critical in a compliance-heavy industry. 

RaceTrac: Monthly POS Packs for 370+ Convenience Stores 

RaceTrac’s in-store promotions shift every month, creating a rolling puzzle of signage, decals, and shelf talkers destined for more than three-hundred-seventy locations. All Points prints, profiles, and kits each 100-piece pack, then delivers them store-specific and shelf-ready. The result: on-time arrival, reduced in-store labor, and no more warehouse space tied up at corporate headquarters. Proof that kitting discipline can make even routine retail programs run smoother and cheaper. 

Best Practices for Short-Run, High-Touch Kitting 

High-touch projects live or die by process discipline. Conveyor lines excel at repetition, but influencer mailers and seasonal boxes demand nimble work cells staffed by associates who know why that bow has to sit exactly at two o'clock. We train each team on the brand brief, not just the pack-list, so a mis-oriented logo or scuffed sleeve never slips by. 

‍

Quality control moves upstream as well. Instead of a single end-of-line check, we build micro-inspections into every material hand-off. If the foam insert arrives with a color defect, the work cell flags it before 1,000 wrong-shade pieces make it into boxes. Photos of first-article kits, front, back, open, are sent to clients for same-day approval, creating a reference standard everyone can hold in hand. 

‍

Short runs also mean constant changeovers, so we map each SKU’s physical footprint on modular pick carts. Switching from scented candle kits to coffee grinder bundles is as simple as swapping shelf labels and updating the barcode scanner prompts. No downtime, no confusion, no half-packed orders left on the dock. 

‍

‍

‍

Managing Timelines, Components, and Last-Minute Curveballs 

A kitting timeline is best built backwards. We start with the in-hand date, then layer in shipping transit, assembly hours, inbound freight, and finally buffers for supplier delays. Clients see a Gantt-style snapshot, red lines marking “drop-dead” component arrival. When a vendor misses a date, we spot it at the first scan and trigger contingency stock or overtime shifts before the cascade hits launch day. 

‍

Component sourcing is part science, part negotiation. We maintain a vetted vendor network for boxes, tissue, and wag. Each with tiered MOQs and lead–time profiles. Need 250 holographic envelopes fast? We know which printer can turn them inside three days and which requires ten. For longer-lead imported items, we sometimes air-freight 20 percent of units so photography and influencer seeding can start while the rest sail ocean freight. Flexibility beats wishful thinking every time. 

‍

Last-minute changes are inevitable. A client decides the tissue should be blush, not coral. A QR code must redirect to the new offer page. Because All Points prints labels, inserts, and even short-run packaging in-house, we can pivot within hours, not weeks, and we only scrap unprinted stock, not thousands of pre-printed cards. 

‍

Feature Highlight: In-House Packing + Insert Printing = Fewer Vendors, Faster Results 

‍

Traditional kitting often bounces between three vendors: one prints inserts, another assembles kits, a third shapes them. Every hand-off risks damage, delay, and finger-pointing. All Points consolidates the entire workflow under one roof. Digital presses sit a hundred feet from the kitting line, so a corrected insert can move from PDF to packed carton before the ink dries. Variable-data printing lets us merge first names, discount codes, or numbered certificates directly into each card. No peel-and-stick labels, no extra labor. 

‍

Because the presses feed data to the same WMS that drives pick instructions, a scanner verifies that the right insert lands in the right carton. That tight feedback loop chops full days off timelines, cuts freight cost between vendors, and, most importantly, keeps creative control in the brand’s hands instead of lost in transit. 

‍