Intro to Custom Boxes

Here’s everything you need to know about custom product boxes to get started.

The Advantages of Custom Product Boxes

  • Brand Enhancement

    Custom boxes physically represent your brand, allowing for the incorporation of your logo, color scheme, and brand messaging. This consistent branding helps increase visibility and establishes a strong brand identity, making your products instantly recognizable.

  • Improved Customer Experience

    Receiving a uniquely designed package can significantly enhance the unboxing experience for your customers. A memorable unboxing experience delights the customer and encourages social sharing, potentially attracting more customers to your brand.

  • Cost Effective

    Although there might be an upfront investment, custom boxes can be cost-effective in the long run. By optimizing the size and material based on your product’s needs, you can save on shipping costs and minimize the use of unnecessary packing materials.

Our Custom Box Styles

Build a Box - Custom Boxes | Intro to Boxes

SHIPPING BOX

The shipping box (RSC regular slotted container) is the most commonly used box style for shipping and storage. Modifications include stapled sides, taped sides, hand holes, full overlapping flaps, partial overlapping flaps, HSC style where one side of the box has no flaps, automatic folding bottom, and snap locking bottom.

Build a Box - Custom Boxes | Intro to Boxes

MAILER

Mailer boxes (also known as RETT roll end tuck top) are flat, die-cut boxes that are easy to assemble with a simple self-closing design—commonly used for subscription box delivery.

Modifications include front locking tabs, side dust flaps, catalog lock, and thumbhole for easy opening.

Build a Box - Custom Boxes | Intro to Boxes

LITERATURE BOX

The literature box (OPF one-piece folder) is ideal for shipping books, binders, and picture frames. Used often in the printing industry, this style is made to be folded around the product. Modifications include variable depths, self-locking tabs, and air cells for protection.

Build a Box - Custom Boxes | Intro to Boxes

RETAIL BOX

Retail boxes (RTE reverse tuck end) are mainly used for retailing your product instead of shipping. It is self-locking and requires no tape or glue to set up. Modifications include same-side tuck end, catalog, automatic bottoms, snap lock bottom, and thumb hole for easy opening.

Build a Box - Custom Boxes | Intro to Boxes

TRAY

A tray (also known as a DST design style tray) is commonly used for large, narrow items like picture frames, although they are also used on the top and bottom of pallets. The flaps can be glued, taped, or stapled. Modifications include a roll end tray, roll side tray, corner cut tray, and telescoping option.

Build a Box - Custom Boxes | Intro to Boxes

DISPLAY BOX

A display box is a type of packaging designed primarily for showcasing and promoting products in retail environments. Unlike standard shipping boxes, which are intended to protect items during transit, display boxes are crafted to present products to consumers attractively, often at the point of purchase.

Work With a Wholesale Packaging Provider That Offers Customizable Options

Build A Box works closely with clients to build a custom package or box that meets their needs. Contact us today to start building your solution.

BOX STRENGTH

Box strength can be a bit confusing and will vary based on packing applications, however the process can be narrowed down to four simple strengths.

Standard:  Standard strength, single-wall box is not recommended to exceed 65  pounds and 75 inches in girth (length + width + depth).

Industry specification: 200lb burst strength or 32 edge crush test

Build a Box - Custom Boxes | Intro to Boxes

Strong:  A more durable single-wall box is not recommended to exceed 90 pounds and 90 inches in girth (length + width + depth)

Industry specification: 275lb burst strength or 44 edge crush test

Build a Box - Custom Boxes | Intro to Boxes

Standard Double-Wall:  Standard double-wall box is not recommended to exceed 65 pounds and 75 inches in girth (length + width + depth).

Industry specification: 200lb d/w burst strength or 42 edge crush test

Build a Box - Custom Boxes | Intro to Boxes

Heavy Duty Double-Wall:  Extra strong double-wall box is not recommended to exceed 120 pounds and 100 inches in girth (length + width + depth).

Industry specification: 350lb d/w burst strength or 51 edge crush test

Build a Box - Custom Boxes | Intro to Boxes

BOX COLOR OPTIONS

Build a Box - Custom Boxes | Intro to Boxes

Kraft on Kraft: The standard corrugated color (brown) of most plain boxes on the inside and out.

Build a Box - Custom Boxes | Intro to Boxes

White on Kraft: An off-white color (similar to eggshell white) on the outside and kraft (brown) on the inside. This is the most common white box used in the industry.

Build a Box - Custom Boxes | Intro to Boxes

Premium White:Bright white on the outside and kraft (brown) on the inside. Premium white boxes are mostly used when printing fine details and are great if your box is for retail and sitting on a shelf. It is not recommended for a shipping box.

Build a Box - Custom Boxes | Intro to Boxes

White on White:White inside and outside can also be made. However, there are some restrictions/minimums with this type of material. If you’re considering this color, let your design expert know if this is right for you.

Build a Box - Custom Boxes | Intro to Boxes

Colored Boxes:These can be made with a print process called flood coating. However, there are some restrictions/minimums, so check with your design expert to see if colored boxes are right for you.

CUTTING DIES (TOOLING)

A cutting die is a tool made from heavy plywood and steel rule, which is bent into the shape of the item to be made and inserted into the plywood: cutting dies are used to make items such as mailers, displays, file boxes, and any item that has a self-locking or self-assembling design. The cutting die is mounted into a die-cutting press, which stamps out the item. There are two types of cutting dies: flat and rotary. Flat-cutting dies are used for small quantity orders of 1,000 parts or less. Rotary cutting dies are used in high-speed presses for projects of 1,000 parts and above. Costs for cutting dies vary greatly, depending on the size, complexity, and type of die required.

PRINTING PLATES

Printing plates are made of highly specialized photopolymer materials and are used to print line art and text directly onto corrugated boxes. This process is known as flexographic printing, and a printing plate is required for every image. These plates are mounted onto a sheet of material that matches the item, so the print will be in the proper position each time the item is made. Items printed in multiple colors require a separate set of plates for each color. Traditionally, all printing plates are made and sold through third-party trade shops, which sell them to the box manufacturer, who in turn sells them to the box customer. The cost of printing plates varies greatly, depending on the size, complexity, and number of colors.

LEAD TIME

Standard production time is 7 to 10 days after the final artwork or sample approval. However, we don’t guarantee any lead times. Check with your design specialist, and we may be able to meet your needs in a timely manner.

RECYCLING

The boxes we produce are 100% recyclable and made in the USA. This is a great way to promote your product and show that your company is eco-friendly.

Let’s Talk About Your Custom Box Needs

Fill out and submit the form, and one of our representatives will be in touch with you shortly.