This guide walks through every decision in ordering custom packaging, from choosing a board material to approving a proof, so you can specify packaging confidently whether this is your first 50-box run or your tenth wholesale order. It is written by the team that runs the presses, not a marketing desk.
Step 1 — Understand the board types
Board material is the foundation of every packaging decision. It determines strength, print quality, cost and sustainability.
- Folding carton (14pt–24pt): light products, retail shelf, sharpest print, lowest cost at volume
- E-flute corrugated: light shipping with near-carton print quality
- B/C-flute corrugated: heavier shipping and stacking strength
- Rigid chipboard (1.2mm–3mm): luxury weight, premium tiers, no folding
- Kraft board: recyclable, natural, ideal for one or two colour print
Step 2 — Choose a box style
Box style is the structural format — how it folds, closes and opens. The product and the fulfilment process decide it.
- Roll-end tuck-front mailer for eCommerce parcels
- Straight or reverse tuck end for retail cartons
- Auto-lock bottom for fast hand assembly
- Lid and base or magnetic closure for gifting
- Sleeve and tray for premium multi-part opening
Step 3 — Pick a print method
Digital printing wins under 750 units and for frequent artwork changes — which is what makes low MOQ runs economical. Offset wins above that on cost per unit and Pantone accuracy. Flexo is the choice for corrugated shippers and large single-colour runs.
Step 4 — Add finishing
Finish is what the hand feels. Matte or gloss lamination protects the print; soft-touch adds a premium tactile feel; foil stamping and spot UV highlight a logo or pattern; embossing adds dimensional detail. Add finish to the one element that matters most — usually the logo — rather than every surface.
Step 5 — Approve a dieline and proof
Before anything goes on press, you receive a free dieline and a 3D digital proof. Revisions are free until the layout is exactly right. You can optionally order a printed sample to test fit, strength and colour in the real world. Nothing is a surprise.
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Need a specification for your product? Request a free quote or browse our packaging products.