In fact, the State of Consumer Behavior report by Raydiant shows that 46% of consumers still prefer to browse products and shop in person rather than online. Another study by Nielsen also shows that 82% of consumers are now doing in-store shopping again after restrictions have been lifted. These statistics indicate that a significant number of consumers still crave in-store experiences.

However, changes in consumer behavior also necessitate retail space. Today, visual merchandising has become both an art and a science, as retailers go beyond aesthetics to deliver value to the customer and drive sales. 

Here, we’ll discuss product displays and how they can be used to help businesses boost engagement and sell more items. We’ll also share ideas on how to use cardboard display boxes for product display. Read on to learn more about transforming your retail shop and creating awesome customer experiences.

Why Product Displays Matter

Before we delve into the details, we must first understand what a product display is and why they remain important for a company.

Product displays are creative presentations of a store’s products or services. They are an integral element of merchandising and often serve as the first point of interaction with customers. 

In a retail environment, quality product displays engage the customer and entice them to make a purchase. They also contribute to consistent branding and can create a positive impression of what a company represents. Used effectively, they can significantly boost sales and help earn customer loyalty.

15 Common Types of Product Displays

1. Storefront Window Displays

Storefront displays are the first touchpoints of a company with a potential customer. These are presented in the front window of a store and are designed to attract passersby.

A storefront display must be striking enough to catch the attention of people within the few seconds it takes them to pass by the front window. An effective one can spark interest and compel a customer to discover more about the products inside the shop. It leaves a positive first impression that can advance a customer from the awareness stage to the consideration stage.

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2. Freestanding Displays

For larger items or products that need to be presented in a more organized manner, standalone displays are better than dump bins. Instead of putting the products in a single box, they are arranged on hooks or shelves in a freestanding display. 

This type of display is accessible from all sides and is great for cross merchandising. It can be placed strategically in the middle of aisles to break the traffic flow and engage shoppers.

3. Pallet Display

Pallet displays are similar to freestanding displays, but they are placed on a pallet instead of directly on top of the floor. These are often seen in big box stores or wholesale clubs where large volumes of products are sold. 

Even with large quantities and heavy items, they can still be moved around with ease using a small pallet truck. They can be placed in wide open spaces with high traffic to encourage fast turnover of products.

4. Display Tables

Display tables are a bit similar to showcase displays, but they don’t have glass enclosures. With the open display, a customer will feel more comfortable taking a closer look at the products presented. 

Display tables are also perfect for showcasing items that form a set or have complementary uses, such as small home appliances, kitchen tools, or outfits with matching accessories. They also work great for seasonal items and holiday gift sets.

5. Dump Bins

For large volumes of low-price merchandise that need to be sold quickly, dump bins provide higher visibility and easy accessibility. These are point of purchase displays placed near the checkout counter or in a high traffic area where customers can conveniently grab the featured products. 

These counter displays are usually made with durable cardboard boxes printed with promotions or ads. Since the bins are relatively lightweight, they can be moved to other areas within the store.

6. Gondola Displays

One specific type of freestanding display is the gondola. Like other standalone displays, this is best placed in open areas with high traffic. A gondola display is typically made of steel frames with a peg board. The pegs can be adjusted based on the products being promoted. 

They can also be single-sided, double-sided, or wraparound. This versatility makes it a good option for brands with multiple product offerings to explore.

7. POP Displays

Regardless of the type of retail space, there is likely a point-of-purchase (POP) display that highlights a specific product or announces a new promotion. 

POP displays are ubiquitous elements in in-store marketing. They are often made of cardboard and printed with ads, promos, or deals. A POP display can be standalone displays or small shelf inserts placed in any open space that can lead a customer to purchase certain products. Specific types of custom cardboard POP displays are also included in this list.

8. End Cap Displays

Also another type of display targeting customers at the point of purchase, end caps draw the attention of customers passing through the end of an aisle. These are shelves at the end of an aisle where new inventory or store specials are displayed to build product awareness and boost sales. They can be used also for cross merchandising complementary products of the same brand.

9. Inline Displays

For business brands that share shelf space in large groceries or box stores, inline displays can be used to create differentiation from other brands. They are placed on a regular shelf to make a brand stand out from other similar products. These work well in directing customers’ attention to small and easy-to-grab items.

10. Showcase Displays

Showcase displays are typically used for valuable high-end merchandise or high-interest niche items. The display cases are made from clear materials such as plastic, glass, or plexiglass. They are encased on all sides to keep the products on display secure. They are accessible from one side or from several sides but require the help of a store clerk.

11. Retail Shelf Displays

Retail shelves are fixed, and sturdy shelves are used to display a wide assortment and range of merchandise. These can be single-sided shelves placed along the walls or double-sided ones that form aisles in the store. These are the typical product displays we see in grocery stores, box stores, and big pharmacies.

12. Glorifier

A glorifier is a small clear box made from glass or plastic. It is placed on a standard shelf to highlight a specific product. It acts as a pedestal or podium for products being pushed for higher sales.

13. Countertop Displays

Countertop displays encourage customers to buy small items or products on promotion. These are best placed on the checkout counter to push impulse buys at the point of purchase. However, they can also be strategically placed on display tables and shelves throughout the store. They are best used for displaying and organizing small merchandise.

14. Mannequins

Mannequins also display products. They help customers visualize how pieces of clothing or accessories look when worn. They can also be used to recommend items that can go well together and the styles that are currently on trend. To further boost sales, have the items the mannequins are wearing on a nearby rack or shelf.

15. Immersive Displays

Immersive displays elevate the buying experience by giving customers a more personal engagement with the products. They follow a central theme and tell a compelling story that customers can relate to. 

One example of an immersive display is a camping setup complete with an erected tent, sleeping bags, camp stove, and other camping paraphernalia. This image helps customers envision the environment where they would be using the products.

A Practical Guide to Product and Purchase Displays

1. Be Economical 

Although they are effective in boosting sales, there is no need to spend a huge chunk of your marketing budget on a product display. Utilize space and materials that are already available to avoid additional expenditure. Upcycle materials and fixtures to create one-of-a-kind displays. Resourcefulness and creativity are often the only things you need to build eye-catching displays.

2. Make Them Versatile

Many product displays are seasonal in nature but some can be used long-term. In creating these types of displays, strive to make them versatile so they can be used to exhibit almost any type of merchandise. Make them in such a way that they can easily convey different messages and fit almost any business theme.

3. Create a Multisensory Experience

Most people focus on the visual aspect of a product display. But aside from catching the eyes of potential customers, your display must also engage their other senses. So go beyond the visuals and create a multisensory experience. 

Play music that appeals to your target customer. Use scent marketing to stir positive emotions and trigger good memories. If you are selling food or consumables, offer free tastes or samples. The more senses you entice, the higher the probability of converting into sales.

4. Consider Both Demographics and Psychographics

Demographic data have been traditionally used in developing marketing strategies. Even in creating quality product displays, it is important to identify the age, income, education, geographic location, and other such data of your target customers. These help you understand them better. 

However, you must go beyond demographics and dig deeper into your customers’ psychographic information. Psychographics will tell you what their interests are, what drives their purchase decisions, and what type of lifestyle they live. Having a more in-depth knowledge of your customers will enable you to create displays that truly connect with them.

5. Keep the Price Tags On

Removing the price tags on a product display can lead to a lost sale. Some customers may not bother to ask about prices and just assume that the product is beyond their budget. If your product is of high-quality, they may even think that it is priced much higher than the actual price. So keep the tags on.

6. Placement Matters

Even the most attractive product display will not convert into a sale if they are not visible. The location of your product display would matter significantly. Make sure new products and bestselling ones are displayed in high-traffic zones. Accessories and small items can disappear from shelves, so place them near the checkout counter.

Another crucial area you must pay attention to is the decompression zone. This is the area inside the store right near the entrance. Use this zone to create a transition from the outside world to your store by placing a product display that showcases your company’s image. Keep the area free of clutter to make your store seem more inviting.

7. Use Your Displays to Educate

Aside from showcasing your products, use your displays to provide customers with more information about the items you offer. Indicate useful tidbits on unique features or functions. Illustrate how the featured product can be used. 

You can also share new trend ideas. Consumers are more likely to buy a product that they feel they have more knowledge of.

8. Keep Displays Clutter-Free

It may be tempting to place all of your new products or bestsellers in a single product display, but avoid doing so. Overcrowding your display can overwhelm customers. Instead of displaying too many disparate products, focus on a single point of interest. You can highlight a single product or use a unified theme that connects several items.

9. Keep Your Displays Fresh

Change your product displays on a regular basis—once a week, at the least. Having a new one every week keeps your store looking fresh and gives regular customers something to look forward to every visit. Frequent passersby are also more likely to notice your store if your storefront display changes constantly.

10. Maintain Your Product Displays

Most retail market stores have specific areas for their product displays. If you have a permanent location for these, make sure it is always clean and organized. Check the fixtures such as lighting and platforms as they can break or become worn down over time.

How to Make a Quality Product Display Case That Attracts Customers

1. Make It Readily Visible

Visibility is a huge factor in the success of all promotional materials, including product display. Place your display case where customers can readily see it. Choose a location where there will be little space lag between the time a customer sees the display and the time they react to it.

2. Use Actual Products

Ideally, actual products should be featured in your product display case. However, there may be certain circumstances where this is not possible, such as when selling perishable food items. What’s important is that your display shows the customer what the product actually looks like in real life. Instead of using a flat intangible picture of your product, use a more realistic representation.

3. Be Bold

Your product display should help you stand out from the competition. Be bold and create contrast using eye-catching colors and images. Make your display case Insta-worthy by choosing a design that would make people want to snap a pic and share it online. Remember that there are currently over 3.6 billion people using social media worldwide, and many of them love sharing images and graphics that stir interest.

4. Be Innovative

Strive to be original with your design and think outside the box. Use modern techniques to make your displays standout.

5. Make Your Display Cohesive

Avoid a cluttered display especially when cross merchandising. Group related products in one display or have a single cohesive design that ties all the items together. Every item in your display products list must interact or complement the other items. 

6. Set the Mood with Lighting

Use lighting to set the tone for your product display. A spotlight can focus attention on a featured product. Soft lighting can be used to create a glowing effect that captures the eyes of customers.

7. Use Motion to Attract Attention

Anything that moves is bound to catch people’s attention. Incorporate some form of movement in your product display to draw more people in. Try a rotating carousel for small items on a display table or use a small fan to create breeze in a summer display.

8. Offer An Experience

33% of consumers prefer shopping in person because they want to interact directly with the products. They want to personally see and feel the products before purchasing them. High-tech interactive displays can enhance their buying experience, which in turn, can increase the odds of a purchase.

9. Make a Statement

Social media has made people more vocal about their advocacies and opinions. Use your product display to make a statement that your business stands for. 

Mannequins that are plus-sized or have dad-bods are now more common, as they help promote self-love and acceptance of one’s unique appearance. If your company promotes sustainability, make sure it is evident in your product displays.

10. Leverage Technology

We are now living in the digital age where technology plays a vital role. Leverage modern tools to amplify your product display. 

About 8 out of 10 customers enter a store because of a digital sign that caught their interest. Find ways to incorporate one in your storefront display. You can also use videos or interactive tablets in your in-store displays to capture the interest of your customers. 

What You Must Absolutely Avoid When Creating Custom Displays

1. Placing Unrelated Items Together

The human mind seeks order. It constantly looks for patterns and systems. This is why clutter and disorganized items create anxiety in many people. For your customers to have a pleasant shopping experience, do not place mismatched displays of unrelated items.

2. Displaying Too Much or Too Little

Although consumers look for variety, placing too many products or multiple product types can overwhelm them. It can make it more difficult for them to choose which one to buy. 

On the other hand, not displaying enough products can create the impression that your product portfolio lacks variety. Thus, balance is key to product displays. You must have just the right number of items that provide ample choices without causing confusion.

3. Focusing Too Much on the Display, Not on the Product

Product displays should look great, but keep in mind that the focus should be on the products you want to sell. Avoid displays that are too flashy—they can distract potential customers from the actual products. Your product display should enhance the products instead of taking the spotlight off them.

4. Using Dark Backgrounds on Window Displays

A dark background makes the glass behave as a giant mirror. A person who looks through a window with a dark background is bound to see his own reflection, too. This may steal attention away from the products on display. 

5. Filling Every Corner or Space With Displays

Resist the temptation to cram every available space on the walls, shelves, and aisles with product displays. Having a white, clean space where there is nothing but an empty spot creates a breathing room in your store. Far from being a waste of space, it actually helps highlight your product displays by creating a focal point in the store.

Choosing the Best Material for Product Display Boxes

A product display often involves the use of boxes made from different materials such as plastic, metal, wood, or cardboard. The best material for your product display will depend on what products you are showcasing, where you will be placing the display, and how long you plan on using it. 

In choosing the material for your display boxes, consider your intended use, specific requirements, environmental impact, and cost.

Comparison of Different Materials for Display Boxes

Benefits of Using Cardboard Display Boxes

Cardboard is the most popular choice when it comes to product display boxes for retail marketing. Here are seven reasons why it is the most preferred material:

• It is cost-effective. Cardboard prices are lower compared to wood, metal, and plastic.
• It has a quick turnaround time. Cardboard boxes can be manufactured faster than other materials even with bulk orders. This quick turnaround time makes them perfect for seasonal marketing campaigns.
• It is versatile. Cardboard is easy to cut and mold into unique shapes. Shelves, pockets, folds, and other details can also be easily integrated into its design.
• It is easy to assemble. Most cardboard boxes are designed to unfold and fit together like puzzle pieces. They do not require tools and other materials for assembly.
• It is easy to transport. Cardboard is the most lightweight material for display boxes. It can also be disassembled and folded flat for shipping.
• It is durable. Cardboard may not last as long as metal or wood, but it can withstand use for an entire marketing campaign period.
• It is environmentally friendly. While not all cardboard is eco-friendly, many of them can be easily recycled. Vegetable-based inks can also be used to print on them to make them more eco-friendly.

8 Common Types of Cardboard Display Boxes

1. Counter Display

These are small and compact boxes designed to be placed on top of display tables or countertops. They are great for retail sales of small items, such as pens, candies, makeup, and other similar-sized merchandise.

2. Power Wings

Also called sidekicks, power wings are small displays on end caps or shelves. They increase a shelf’s basket size and allow brands to highlight new products or promotional offers. They are often used for small lightweight items, like sample-sized products, magazines, cosmetics, and OTC pharmacy products.

3. Inline Displays

Inline displays or on-shelf displays help businesses set themselves apart from a shelf full of competing products. These are usually trays or open boxes with additional branding to break the visual monotony of similar products lined on the same shelf.

4. Brochure Holders

Some businesses such as travel agencies, salon services, or B2B companies advertise their products and services but do not necessarily offer them in a particular store. Instead, they provide brochures which the customer can get while shopping or waiting in line. 

Brochure holders not only give their brand and message more visibility but also keep marketing collaterals organized. These are usually placed on the checkout counter, reception desk, or takeout window.

5. Floor Display Stand

Cardboard floor displays may have 2-7 layers of shelves where several products can be arranged on display. Some have pegs and hangers instead of layered shelves. Others combine both shelves and pegs for a wider variety of product display.

6. Pallet Display

Cardboard pallet display racks combine storage and display. The bottom part is often used to store stocks while the top rack is used to display the product being promoted. This type of display is lightweight and can be conveniently moved throughout the store.

7. Cardboard Trolley

Cardboard trolleys are ideal for mobile marketing campaigns. They combine the portable storage of trolleys and the visibility of display boxes. They are usually printed with ads and used in shows and conventions where mobility is required.

8. Dump Bins

Cardboard is also a low-cost material for dump bins. They can be easily printed with visually appealing designs and work great for seasonal promotions. Their lightweight materials also make them easy to move around the store.

Other Cardboard Promotional Items

Aside from display boxes and custom packaging, cardboard can be used for other promotional items and POP displays.

1. Shelf Stoppers

Shelf stoppers or shelf takers are signs placed on a retail shelf. They are positioned perpendicular to the shelf to attract customers and to draw their attention directly to where a featured product is displayed. Cardboard shelf stoppers do not require floor space, are easy to attach to shelves, and provide brands an affordable way to increase product visibility.

2. Ceiling-Hung Signs

Like shelf stoppers, ceiling-hung signs do not require floor space and provide a low-cost way to increase brand awareness. These signs are hung from the ceiling to draw customers to the area where products are shelved.

3. Cardboard Standees

One way to gain more awareness for a brand is to use cardboard standees. These are 3D structures of the actual products or the product endorsers. They can also be designed to resemble free-standing product displays that have unique shapes.

Make a Statement with Customized Cardboard Display Boxes

Cardboard display boxes are customized according to the specific size, design, and style that a company needs. When having your display boxes customized, consider the products you will be showcasing. Having a product-oriented display ensures that the spotlight will be on your product and not on the box. Also make sure that the box has the physical integrity to support the product you will be displaying on it.

When featuring small items, like cosmetics, include dividers or pockets in your display box to keep the items organized. If the box will be placed in an environment exposed to moisture, opt for waterproof or water-resistant cardboard.

To get the best cardboard display boxes, partner with a manufacturer who is willing to talk with you about your customization options and go the extra mile to meet your requirements.

Refine Packaging is the top choice for the world’s Inc 5000 and Fortune 500 companies. With super fast production times, affordable pricing, and a sky’s the limit attitude, we’ll help you turn your custom packaging into a competitive differentiator. Contact us today and a dedicated packaging specialist will guide you through every step of the custom packaging process without breaking a sweat.

The post Ultimate Guide to Product Display and Custom Cardboard Display Boxes appeared first on Refine Packaging.

Implementing green packaging in your brand’s operations is a necessity now more than ever. In this guide, you’ll find out why. 

What is Kraft Packaging?

About 32% of all plastic used in the packaging industry won’t end up in the trash. The problem with that is plastic takes hundreds of years to decompose. In other words, aside from the ones that have ended up in the incinerator, every piece of plastic ever manufactured still exists to this day.

Kraft is an eco-friendly alternative to plastic packaging and might be the world’s answer to the ever-growing plastic pollution. It is a common material used for packaging products in industrial and commercial operations. Kraft packaging is made from a renewable resource, which is biodegradable and recyclable. However, unlike regular paper, kraft paper can be made from any type of wood species.

During the kraft process, the natural wood is ground into a pulp and then treated with white liquor, which is a mixture of sodium hydroxide and sodium sulfide. It separates the lignin and the cellulose. Due to its reduced lignin and high sulfur content, kraft paper is very sturdy.

The kraft process is better for the environment, as it requires fewer chemicals, which can be recovered and reused without affecting the quality of the output.

Kraft has a natural brown color because of the wood pulp. Although it can be bleached, this process can weaken the fibers that make the material strong. The extra bleaching step can also drive up the manufacturing costs of the kraft packaging. 

Regular Paper vs. Kraft Paper

Kraft papers are arguably more sustainable and eco-friendly than regular paper materials. The kraft process is a self-sustaining method used to produce kraft papers and boards. Any type of wood can be used in this method, including pine and bamboo, which aren’t options for traditional paper making.

Since the kraft process results in lower lignin and higher sulfur content, kraft paper is sturdier than regular paper. It holds up well against heat, moisture, grease, and rough handling during shipping, making it a superior choice when it comes to packaging. It can be used to store food and beverage, cosmetics, appliances, and various other products.

Compared to general packaging materials such as plastic, kraft paper is more affordable. Despite its strength and thickness, it won’t add much weight to your package, allowing you to save on shipping costs.

The growing demand for kraft paper and eco-friendly packaging might further reduce their costs in the years to come.   

Benefits of Kraft Paper Packaging

Why are so many businesses willing to switch to kraft paper boxes packaging? Aside from the rise in demand for sustainable packaging, using kraft has a range of advantages.

1. They Are Versatile

From envelopes and food-grade boxes to tuck-top kraft boxes and folding cartons, kraft paper can be turned into all kinds of packaging materials. No matter what type of product you sell, you’d have the option to use some form of kraft paper packaging.

If what you need isn’t available on the market, you can have custom packaging to fit your products.

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2. They Are Durable

Kraft paper boxes packaging is very strong and robust. It can withstand rough handling and shuffling in transit, which enables brands to protect delicate products from damage.

Natural kraft paper lasts longer than its recycled alternatives because it mostly contains pure wood pulp. The raw materials are harvested from tree trunks and contain high concentrations of fiber. Recycled kraft paper will usually contain bark and other materials, which reduces its strength.

Although it’s durable, kraft tends to lose its strength when exposed to water. Thus, it’s usually treated with special resins when used to wrap wet products.

3. They Are Eco-Friendly

Kraft packaging reduces your carbon footprint because it is 100% eco-friendly. Even if it isn’t segregated in the trash, the kraft material will decompose in the landfill in a matter of weeks, leaving no negative impact on the environment.

Take note that kraft paper must be free from any plastic films and special resins if you want it to be 100% compostable. Let’s say you use kraft cut-out windows for your product packaging. Adding a non-compostable material, like a gloss lamination, over that cut-out space won’t make your packaging 100% eco-friendly.

Instead, you can leave that cut-out space open. Your customers can have a closer look at your products, while you stay true to your promise to deliver their goods in eco-friendly packaging only.

It’s also a recyclable material. You can recycle old kraft boxes and turn them into new packaging.

4. They Are Cost-Effective

Natural kraft paper is more affordable than plastic packaging. Even though they are sturdier than regular paper, their strength and durability don’t add to their weight. The kraft material won’t cost a lot of money in terms of shipping.

Buying kraft boxes wholesale can deliver a great deal of relief to a small or medium-sized business. The prices are significantly lower if you buy in bulk.

5. They Are Customizable

Paper kraft packaging can be manufactured in a variety of colors, dimensions, and shapes. Also, natural kraft paper is print-friendly. Using modern printing machinery, you can personalize your packaging in a variety of ways. You can print logos, attractive designs, and other product details directly on the material.

Custom kraft boxes with personalized prints usually cost extra money. If you want to personalize your boxes without spending too much, you can decorate them with stickers, ribbons, and stamps instead.

6. They Are Print-Friendly

As mentioned, kraft paper boxes packaging supports varying printing techniques, including digital printing and lithography. You may also use embossing and foil stamping techniques to enhance the look of your brown paper kraft boxes.

Whether you want to use soy-based or water-based ink, your prints will come out clearly on the kraft material. You can grab the attention of consumers and increase the promotions of your product. 

Color Classifications of Kraft Paper Boxes

Kraft paper boxes have a natural brown hue. However, this natural hue can be turned into white and other colors through bleaching and other chemical processes.

1. Brown Kraft Paper

Natural kraft paper is dark brown with visible impurities on the surface. If you bleach kraft, you can reduce those impurities and brighten the color. However, you’ll reduce its strength in the process. Hence, for shipping boxes and outer layer packaging, which protect your products from dust and moisture, natural brown kraft paper is more ideal.

2. Black Kraft Paper

Black kraft paper has a smooth surface with a slight glossy sheen. It is used mostly as backdrop for picture frames because of its sleek and professional appearance. Sometimes, it’s used for bulletin boards, banners, and wrapping.

3. Bleached Kraft Paper

Naturally brown kraft paper can be bleached to produce a lighter color. This type of kraft paper is often used in the restaurant industry as a cost-friendly alternative to linen tablecloths. It can also be used as wrapping paper for packages.

Although the bleaching process may weaken the fibers that make kraft paper durable, there are other ways to lighten the material without affecting its strength.

4. Single-Sided Smooth Kraft Paper

This type of kraft paper has a smooth and bright side, which has minimal impurities. The other side has that brown hue that kraft paper is known for. It also has the impurities of natural kraft paper. 

Types of Kraft Paper Packaging

There are different types of kraft paper packaging on the market. In general, these packaging materials are very sturdy. However, their strength and application may depend on the source of the wood as well as the manufacturing processes used.

1. Virgin Kraft Paper

Virgin kraft packing is made from raw wood pulp. This natural wood is harvested straight from the tree before it is manufactured into brown paper.

Even though virgin kraft paper isn’t very thick or heavy, it has high tear resistance and stiffness. It is an ideal packaging material for heavy-duty applications and is used to make packaging tapes, corrugated mailer boxes, and more.

The naturally brown hue of the kraft paper adds to its uniqueness, making it look rustic and homemade. Plus, unlike whiter packaging alternatives, the rough handling process isn’t as obvious on kraft paper boxes.

2. Recycled Kraft Paper

Coated recycled board is made of recycled content, such as cardboard boxes, books, and kraft materials. They are reduced into pulps before they are turned into recycled paper.

Once kraft paper is recycled, it won’t be as sturdy and tear-resistant as virgin kraft paper. It is great for products that don’t require high tear resistance like cereal boxes, paper bags, and paper cans.  

3. Mixed Kraft Paper

Mixed kraft papers are used for postage boxes and cardboard envelopes. As its name suggests, mixed kraft paper is a blend of sorts. It contains recycled and virgin pulp, which makes it as sturdy as natural pulp. It’s cheaper and more eco-friendly because it contains recycled materials. 

Kraft Paper Packaging Designs

What is kraft paper used for in packaging? Kraft paper boxes packaging is incredibly diverse. From bags to boxes, here are some unique packaging and gift box ideas that you can use with kraft materials.

1. Countertop Display

Businesses with brick-and-mortar shop locations use countertop displays to entice customers to buy more. At supermarkets, makeup stores, and confectionery shops, these are the little containers you’ll see at the counter. These kraft display boxes don’t take up a lot of space. They can hold several small-sized products, which are often very enticing.

With their eye-catching designs and styles, countertop boxes are meant to grab the attention of consumers while they’re checking out. They can also feature product-related information that may influence the purchasing decision of prospects.

2. Food-Grade Boxes

Kraft paper food packaging comes in a wide array of designs to fit a variety of food products. Salad containers, for instance, have at least one big clear window and side buckles to prevent your greens from spilling out.

Takeaway containers, like gable boxes and food bags, may have protective films like oil-proof lamination and heat-retaining coatings to keep the food fresh inside and prevent the grease from seeping into the paper. They may come with flaps that can be ripped out.

By using food-grade kraft boxes, restaurants and fast-food chains can reduce their plastic waste. They can reduce costs as well. 

3. Paper Bags

A kraft paper gift bag may have greaseproof and waterproof finishes to accommodate homemade products such as greasy food and baked goods. Apart from the natural brown color, a paper bag of this type is available in a wide array of colors.

4. Magnetic Boxes

Built with magnetic flap closures, these kraft paper boxes look very sleek and luxurious. You can add custom foam or silk inserts to protect fragile products like porcelain figurines, silverware, and more. This extra step you take to include add-ons can elevate the appeal of your product and improve the brand experience.

5. Jewelry Packaging

For businesses selling handmade jewelry and accessories, kraft jewelry boxes are an affordable and creative way to ship your goods to customers. Adding a foam insert to your kraft box can help protect the delicate trinket inside.

You can have the traditional styles of jewelry boxes, which come with a solid lid that covers part of the base. If you’re willing to spend extra, you can have custom kraft boxes with clear lids. You can also use black kraft boxes. They have a sleek and simple natural look that seems timeless and premium.

6. Pop-Up Tubes

Unique product packaging can give you a distinct advantage in the market. It can get people talking. Pop-up tubes usually have two thermoformed lids that go on each side. Apart from giving the tube structure, the lids also help preserve the flavors of your candies, cookies, spices, and other treats.

7. Tube Packaging

Rigid kraft cardboard can be turned into tube packaging, which can be used to store t-shirts, jeans, and accessories. Its sturdy walls are great for protecting glass bottles like essential oils, cosmetics, and other products. For fragile goods, you can opt to add a foam insert to ensure that your glass bottles stay secure at all times.

Unlike your average folding box carton packaging, this rigid kraft cardboard tube will retain its shape no matter how rough it’s handled during shipment. They are long-lasting and reusable.

8. Cut-Out Window Boxes

Clear plastic windows won’t make your packaging 100% eco-friendly. Instead of adding a see-through plastic over your cut-out packaging, leave the window open. It gives your customers a glimpse of the product inside. It can be used to wrap lightweight products such as hair clips, phone accessories, and other tiny trinkets. It can also be used to secure more delicate products like scented candles, mugs, and wine glasses.

9. Resealable Pouches

Resealable pouches can be made with kraft paper, too. They are great for storing lightweight goods like loose teas, herbs, spices, and dried fruit.  Like the food-grade boxes, they may have an optional clear window. Some may have aluminum foil included, which prevents moisture from seeping into the package.

10. Gift Boxes

Kraft gift boxes come in many shapes, sizes, and designs, such as kraft pillow boxes. These little containers form a curved pillow shape once you stash small gifts inside. A two-piece kraft gift box, on the other hand, has a lid that goes over and fits the tray tightly.

Bigger kraft gift boxes may contain inserts to divide and secure the products inside. Like other kraft packaging options, you’re free to customize them using creative prints to enhance the unboxing experience for customers.

11. Sliding Boxes

Sliding boxes can be used to hold a variety of products, including silverware, clothes, and accessories.

Retailers use kraft sliding boxes to give the customer a unique unboxing experience. If your box is designed to slide open from one side, you can attach a ribbon or a rope pull to the drawer so it’s easier for customers to open the box. An alternative would be a finger notch cut. You can add this to the side of the drawer that opens to ensure a fun and hassle-free unboxing experience.

12. Corrugated Shipping Boards

Kraft corrugated boxes are made of multiple layers of kraft paper. A corrugated board has two thicker outer layers called liner boards. Sandwiched between them is a thinner fluted corrugated sheet, which makes the board highly impact-resistant.

When it comes to wholesale packaging, a kraft shipping box is more ideal than a regular cardboard box. Its tough structure enables you to ship out products safely to consumers. Corrugated boards are used for packaging household appliances, auto parts, and more.

13. Wine Boxes

Custom kraft boxes designed to fit standard wine bottles can give your products a rustic and charming appeal. They may have clear or cut-out windows that show the wine labels. They also have sturdy handles for easy transport.

These wine boxes are great for holidays and special occasions. You can use them to gift your friends and loved ones with their favorite bottles of wine.

14. Mailer Kraft Boxes

Kraft boards can be turned into all kinds of mailer packaging. These boxes are designed to hold and secure a variety of products inside. Unlike your regular shipping boxes or gift boxes, mailer kraft boxes have extra flaps that prevent the products from spilling out during transport.

Printing Techniques for Kraft Packaging

Kraft paper boxes packaging is compatible with most modern printing machinery and techniques. Due to the thickness of kraft material, your inkjet and laser printers might not be the most suitable choice.

Just remember that the results will depend mostly on the printing material you use. Hence, take a close look at the quality of the paper. Make sure to assess its surface and determine whether it creases, cracks, or stains easily. Additionally, try to ask about its physical properties, such as its printing performance, absorption, and optical properties.

Many printing companies would use different printing techniques to achieve the desired colors and designs on the kraft paper boxes material.

Here are the most widely used printing techniques for kraft paper boxes packaging:

1. Flexography

Flexography is a common printing method used on kraft boxes, particularly stand-up pouches. However, it can be used to print on corrugated boards as well. It uses light-sensitive polymer instead of plates to print on kraft cardboard.

Modern flexography machines have built-in die-cut and lamination. This makes it easier to laminate or cut kraft boards. Just remember that die-cutting and laminating kraft boards might cost you extra because of their thickness.

2. Offset Printing

Another widely used printing method that works well on kraft boxes and other forms of kraft packaging is offset printing. Also called offset lithography, this method uses printing plates to transfer an inked image to a rubber blanket before printing it on a kraft material. The printing plates are made of zinc or aluminum.

This type of printing technique utilizes oil-based inks, which are suitable for highly absorbent kraft materials. Using oil-based colors, you can have full-colored designs on your packaging. 

Inks for Printing on Kraft Paper

What colors can you print on custom kraft boxes? The quality and type of kraft board you use will affect the colors of the ink. As a textured and absorbent material, it tends to soak up the ink and reduce its colors.

Since kraft is inherently darker in color than regular paper, some inks might appear more muted on the brown paper.

In general, you should avoid light colors like yellow, cream, and light pink. These colors won’t show up well on the brown paper kraft material. Once you print lighter tones on the board, the absorbent material will soak up the ink. The colors will lose their saturation or intensity. In some cases, the colors might appear differently on the kraft paper or board.

Here are the best colors for kraft material: 

1. Black

All colors will appear slightly muted on kraft paper—except for black. It is less likely to be affected by the natural color of kraft. It is your best choice if you’re printing on kraft material.

2. Darker Tones

Aside from black, darker tones like blues, purples, and greens will look exceptional on kraft materials. Their high saturation and deep colors will appear crisp against the dark brown color of your packaging.

3. Neon Inks

Neon and fluorescent inks, on the other hand, are viscous, which means they sit on the thick kraft board instead of seeping into it. Simply put, neon colors can retain much of their vibrancy when they are printed on kraft boards.

4. White Ink

If you’re printing on kraft paper, white ink is a good option. It looks bright and vivid on your brown packaging, which should draw the attention of your target customer. It gives your packaging a clean and modern look, adding to the rustic appearance of your kraft gift boxes.

This is a relatively new packaging trend. While it is new, you might as well join in and gain a competitive edge.

As with other colors, the quality and opacity of your ink, as well as the material of your kraft box, will determine the final look. 

What Makes Kraft Paper Packaging Eco-Friendly?

Sustainability in packaging isn’t just about having all-natural raw materials. The environmental impact of the production process, as well as the reusability and recyclability of the material, determines the sustainability of the packaging.

1. Materials

Kraft packaging is manufactured using all-natural wood fibers. Although trees are renewable resources, the sustainability of kraft paper also depends on the source of the materials. Ideally, wood fibers should be sourced from a responsibly managed forest.

By looking for the Forest Stewardship Council certification, customers can make sure their kraft gift box packaging is sourced from responsibly managed forests.

2. Production Process

The manufacturing process itself should be another important consideration when it comes to choosing sustainable packaging. How much energy is needed to produce it? How much pollution is created as a result?

To create paper kraft packaging, natural wood fibers have to undergo the kraft process. Compared to other paper manufacturing processes, it requires fewer chemicals. As mentioned, the chemicals used in the production of paper kraft packaging can be recovered and reused, making this process a self-sustaining one.

As for the excess byproducts of the process, tall oil and turpentine, they can be used to manufacture other items.

3. Reusability and Recyclability

The final output of the kraft process, which is the kraft paper itself, is reusable and recyclable. For instance, at home, consumers can reuse their kraft cardboard boxes for storage or transport of household items. They can also be recycled and turned into new packaging materials. 

What is FSC-Certified Kraft Paper?

The Forest Stewardship Council sets standards for sustainable forest management. In North America alone, around 168 million acres of forestland are FSC-certified.

FSC ensures that landowners and wood product manufacturers adhere to responsible forestry practices that include:

1. Protecting the water quality
2. Avoiding hazardous chemicals
3. Protecting the woodlands and natural forest covers
4. Safeguarding the rights of local communities and indigenous people
5. Reducing clear cutting
6. Saving wildlife habitats
7. Promoting transparent governance

Any product that bears the FSC label, including kraft paper packaging, certifies that it is sourced from responsibly managed forests. That means consumers will be able to trace the raw materials that were used to create the kraft gift boxes, as well as the forest where they were harvested from.

In a survey, 76% of retailers and non-manufacturers claimed that the FSC certification adds value to their products. About 88% of them agree that the label helps them convey their corporate social responsibility initiatives to their target audience. Also, 88% of them say that the certification helps them build a positive corporate image. 

What Do Consumers Think of Sustainable Packaging?

Sustainable packaging is important for a modern business because it helps the environment. The world is producing so much plastic, which only ends up in landfills or in our oceans.

Here are some figures from Ocean Conservancy that should concern you:

• 2.5 billion metric tons of solid waste is manufactured globally
• 275 million metric tons consists of plastic
• 150 million tons of plastic is stuck in marine environments around the world
• 8 million tons of plastic enters the oceans every year 

Now more than ever, customers are knowledgeable and aware of the impact of businesses on the planet. To gain the trust of an increasingly eco-conscious market, setting up green initiatives should be a priority in business.

In a study, Trivium Packaging found that 74% of customers are willing to pay extra for products that have green packaging. Of that number, about 25% said that they are willing to pay more than 10% for sustainable packaging.

Nearly 50% of consumers avoid harmful packaging like plastics. Of that number, 68% associate plastic with ocean pollution, which isn’t wrong.

Shifting to sustainable and eco-friendly alternatives in industrial and commercial operations can drastically change the amount of plastic entering the oceans. You can be part of that solution by using kraft paper boxes for your packaging needs. Eco-friendly packaging shows consumers that you care about the planet. 

Kraft Paper Market Updates and Trends

Due to changing customer habits and sentiments, there is an increase in support for the recycling process and demand for sustainable packaging. That includes kraft boxes.

The global market for kraft paper boxes packaging will be worth $22.38 billion in 2028, analysts say. This reflects a 3.8% compound annual growth rate from 2020. Its growth will be driven mostly by this demand for sustainable and recyclable packaging solutions.

Little by little, kraft paper is becoming a primary packaging solution for end-use industries, such as food and beverage, automotive, pharmaceuticals, and cosmetics.

North America is expected to have the largest revenue share in the global market. Its thriving food industry will fuel this growth, along with increasing paper recycling practices in the region.

Build a More Sustainable Future with Kraft Paper Packaging

The commitment to sustainable business packaging is greater than ever. Although the world can’t completely eliminate plastic waste and plastic pollution any time soon, using kraft paper boxes packaging as much as you can and implementing greener alternatives into your operations is a step in the right direction. You might as well do your part to save the environment and the communities you serve.

Refine Packaging is the top choice for the world’s Inc 5000 and Fortune 500 companies. With super fast production times, affordable pricing, and a sky’s the limit attitude, we’ll help you turn your custom kraft packaging into a competitive differentiator. Contact us today and a dedicated packaging specialist will guide you through every step of the custom packaging process without breaking a sweat.

The post Everything You Need to Know About Kraft Paper Boxes appeared first on Refine Packaging.

If so, it’s critical to understand the basic types of labels, materials, and finishes before working with a professional printer. 

Without further ado, let’s dig into the nitty gritty details of product labels, customization options, types of finishes, and so much more!

How Labeling Supports Custom Packaging

Labeling is a component of custom packaging that focuses on promoting and describing your product so buyers know what’s in store for them if they decide to purchase it. This table summarizes the significant role of printed labels in relation to your product’s packaging.

When to Use Printed Packaging vs Custom Labeling

Importance of Custom Label Printing

Product label printing supports your branding efforts in the following ways:

1. Customization

Your custom labels can feature all the content your buyer needs to know about your product. Once you’ve decided on what information and images to include in your label, you can work with a designer or your printer for its layout, shape, and sizing. You can also do it yourself, using an online design tool such as Adobe or Canva.

2. Product and Brand Recognition

A designer can help you come up with ideas that will pique your target market’s interest and make your product easy to distinguish from your competition. Meanwhile, professional printers ensure quality and consistency in the overall look of your custom labels.

When your product has several variants (i.e., flavors or scents), you can design labels that can make sorting easier for wholesalers, retailers, and buyers.

3. Trust Building

Brands can better convince consumers to pick their products if their labels honestly state their contents and benefits. According to research, 97% of beauty product shoppers seek this kind of transparency.

4. Legal Compliance

To comply with industry and government standards on health and safety, include warnings, health hazards, emergency solutions, and other lawfully required information on your personalized labels.

5. Tracking

You can design custom quality labels to help you track products from production to delivery to your distribution points. Bar codes and other stockkeeping unit identification are necessary aids in current warehousing and shipping systems. They’re also useful in the case of product recalls.

6. Marketing Promotions

Labels for products can also feature information such as discounts, coupons, or other special offers to increase your product’s appeal. 

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General Types of Custom Packaging Labels

Labels are made to adhere well to their product’s packaging. Here are the most popular types of printed labels today:

1. Pressure-Sensitive Labels

The most common of all custom labels, pressure-sensitive labels are applied on packaging by hand or machine. They’re made up of a facestock (more info on this later) with or without a top coat and an adhesive with a liner. The details of a label’s anatomy are found in the next section. For optimum adherence, brands and manufacturers consider the surface or material that the label will be attached to.

• Dry peel: Dry peel labels have semi-permanent adhesives. They’re often designed to serve as coupons that buyers can peel off and present to get discounts or to join a contest.
• Reseal: Resealable labels allow customers to seal them back into the product packaging to keep its remaining contents fresh before use or consumption.

2. Shrink Sleeves

Also referred to as a shrink wrap, these polymer plastic films cover entire containers. The film is exposed to heat from a handheld gun or passes through the heat tunnel of industrial label printers to make it fit tightly around the product. Many bottled beverages that need refrigeration have heat-shrink labels.

3. In-Mold Labels

These preprinted polypropylene (PP) labels are injected into a mold where the plastic packaging container is formed. Once the packaging takes shape, the label is already fused into the container. This makes these labels look like they’re part of the container instead of a separate stock placed on its surface. Some laundry detergent bottles and food tubs (yogurt and butter) use this type of labeling.

4. Die-Cut Labels

These labels are made for uniquely shaped containers. They use a die and a press to cut the custom shapes. 

5. Thermal and Thermal Transfer Labels

A warm printhead (direct thermal) or heated ribbons (thermal transfer) print words or graphics on the label material instead of ink. These individually cut custom labels are usually used for price tags, shipping, and bar coding. They have a short life span and are prone to change color when exposed to another heat source. 

The Anatomy of Personalized Labels

Pressure-sensitive labels for products mainly consist of these five parts:

1. Facestock

The facestock is the specialty paper, film, or fabric that contains the graphics and text. Being the main part of the label, it’s the layer where the ink is applied and onto which the top coat and adhesive are anchored. It gives your custom labels structure, shape, and size.

2. Ink

Various types of inks are used to print text, graphics, and photos on the facestock: fade-free UV inks, nearly odorless and affordable water-based inks, and durable solvents that don’t require a top coat. Meanwhile, you can use specialty inks for unique metallic and fluorescent effects.

3. Top Coat

Not all labels need top coats (uncoated), but they’re necessary for facestocks made of plastic film. Top coating helps the ink spread out and cling to these types of surfaces. Meanwhile, varnishes and laminates are examples of top coats for paper labels. Besides providing an aesthetic finishing touch to their surface, this layer protects the print on labels from fading due to moisture, sunlight, or rough handling.

4. Adhesive

The adhesive layer is what sticks to your product’s container or packaging using pressure or heat. Your choice of adhesive material will depend on your packaging material, its shape, the environmental conditions it will be subject to, and your desired level of permanence. 

Here are the four basic types of adhesives:

• Peelable: Labels with removable adhesives can be taken off the surface without leaving any residue or destroying the label itself, compared to permanent ones. But removable adhesives can permanently bond to a surface when they’ve stuck to a surface for an extended time or due to environmental exposure.
• Permanent: Permanent adhesives can stick to moist and rough surfaces. Taking them off will usually result in destroying the facestock. They’re recommended for flat surfaces.
• Semi-permanent: Also called repositionable adhesive, this type lets you peel off labels from their surface in the short-term for adjustment. They settle and harden once reapplied to their new position.
• Freezer: Custom labels with freezer adhesives stay put on the products or their packaging without peeling or cracking—even in below zero settings.

5. Liner

The liner protects your adhesive until it’s applied to a surface. It can be made from paper or film. 

Facestock Materials

Paper and film are the most common materials used for the facestock of custom labels.

Paper

As ink settles well on paper, text and images look very sharp on this surface. Compared to film stock, they’re available in different colors and textures and are more affordably priced.

Paper-based labels are most appropriate for dry and cool indoor applications as they can only handle limited exposure to moisture (water and oil), extreme temperatures, and abrasion. Paper labels are best used for non-perishable goods like canned food as well as household and beauty products like soap bars.

Some common paper facestock examples for labels include:

• White paper: White paper is made of high-quality paper that’s bright and opaque white. It can have a matte, semi-glossy, or glossy finish.
• Metallic paper: Metallic paper gives products a polished sheen. Some of the available colors include gold, rose gold, silver, bronze, and copper bronze.
• Recycled paper: This brown-colored paper stock can give products a vintage, rustic, or handcrafted look. Facestock of this type includes kraft and the black and velvety vellum labels.
• Estate 4: Estate 4 paper is the most durable of the paper stocks due to its “wet strength” or water resistance. It’s also colored white and has a subtle linear texture.

Film

Facestock made of plastic film are tear-free and can conform to the shape of curved or other oddly shaped containers. They’re long-lasting due to their oil and chemical resistance. Film stocks also hold up to spillage, condensation, sweating, and sun exposure. They often have permanent adhesives and can attach to textured surfaces and painted metals.

• Vinyl: Technically called polyvinyl chloride (PVC), these plastic stocks made of ethylene and chlorine have a slight flex and are dishwasher-safe. They can withstand extremely cold environments and can last for up to five years, based on the vinyl formulation. These labels work best on vehicle windows (static cling vinyl) and bumpers, sports equipment, outdoor marketing devices, and frozen food that has to stay in below-zero temperatures for long periods of time. They come in white and clear varieties.
• Polypropylene: Biaxially oriented polypropylene (BOPP) is slightly thinner than vinyl and works well on contoured containers as they can stretch horizontally or vertically (biaxial). They have a medium lifespan (six months to two years) compared to vinyl and polyester stocks. They’re advisable for labeling smaller refrigerated items, such as meat, sauces, dressings, cheese, jams, and beverages. They’re available in white, silver, and transparent versions.
• Polyester: Also known as polyethylene terephthalate (PET) and mylar, polyester facestock can last over 10 years, making it the most durable of all film stocks. They’re ideal for industrial use due to their chemical and moisture resistance. These materials remain intact in extreme temperatures and under UV exposure. They’re the most expensive of all three plastic stocks. Professional printers can offer to make these labels using white, clear, and metalized polyester.
• Squeezable film: This material is best for squeezable bottles and tubes, including lotion, sunscreen, toothpaste, and other beauty and health products.

Different Types of Finishing for Customized labels

Labels need the right finish or top coat to make them last and look good longer. Here are some of the most popular label finishes:

1. Varnishes

Varnishes coat facestocks in clear liquid, making labels smoother and more resistant to spills and scuffs. They cost less than UV coatings and laminates but have the least staying power. A glossy varnish can make image-heavy labels stand out, while a non-reflective matte varnish can produce a subdued but professional effect. You can use spot varnish to highlight specific elements on your custom labels like your logo, brand name, or graphics.

2. UV-Resistant Coatings

This type of finish involves applying a special liquid on a label’s facestock and then curing it in ultraviolet light. The coating later becomes a permanent sunscreen that prevents your text, design, and colors from fading and other possible damage. 

Although this is usually a glossy finish, UV coating is also available in semi-gloss and matte. You have the option to cover the entire surface of your label (overcoat) or just selected sections (spot coat).

3. Laminates

Laminates are a thick film-like coating. They offer the greatest protection against sunlight, moisture, and abrasion. A glossy laminate sharpens the content and color of the label’s facestock while a subtle matte finish can give your custom labels an elegant touch.

4. Foils

A hot foil is composed of metalized PET film with heat and pressure-activated adhesive, which sticks well on glass bottles and cans. Hot foil can give a sophisticated look to custom wine labels. Meanwhile, a cold foil uses UV-curable adhesive, so it’s suited for thinner packaging material like plastic that can’t withstand high temperature. 

Finishing Formats: Roll, Sheet, and Fan-Folded

You can order custom-made product labels by sheets or rolls. Let’s see when to best use each of them.

1. Sheet Labels

When it comes to label sticker printing, sheet labels come in sheets of different paper sizes, although the most common is the A4 size.

Using sheet labels is the best option for short runs or smaller quantities (below 250 labels), including testing out the packaging of your new product or selling seasonal products. But some professional services can also offer this type of printing for a larger project.

2. Roll Labels

Roll labels are spun on a cardboard spool and get printed on using a roll printer. They’re advisable for bulk orders, including those that need specialty ink printing. They can be die-cut in any shape and size. Custom roll labels also work best for labels containing unique content per piece, such as bar codes or shipping labels.

3. Fan-Folded Labels

These pressure-sensitive custom labels are on a continuous backing sheet that folds along its perforations accordion style. This self-stacking format makes a great alternative to the roll format for shipping, address, and barcode labels.

Designing Your Own Labels

How do you come up with a label that will attract customers to choose your product? Here are some pointers.

1. Know Your Target Market and Existing Buyers

What’s your target demographic? It’s important to establish who your buyers are when designing your custom labels—and even your stickers and decals, for that matter. Determine their ages, gender, location, lifestyle, educational levels, income, values, and pain points or challenges that your product can solve. Listen to relevant feedback so you can personalize their experiences. Personalization is generally the difference between successful and disappointing campaigns.

Some relevant statistics to keep in mind:

• 56% of consumers become followers of a brand that “gets them” or understands their needs, and 89% choose to patronize a brand that shares their values.
• 64% of food shoppers spent more on products whose labels contained popular phrases such as “fresh,” “no sugar added,” “whole grain,” or “organic.”

2. Research the Competition

Examine and compare the attributes of your competitors’ marketing and branding materials, such as labels, flyers, stickers, and packaging. Take a close look at the color, typography, imagery, size, shape, and target demographic. What do consumers like and dislike about your competitors’ labels? What colors or other design elements are they drawn to? What are the major differences between your labels and theirs?

Take note of those elements that work well and brainstorm ways you can customize and improve them. Your custom labels should command attention when displayed side by side with similar products in-store. For e-commerce items, check if your labels will register well on the camera for photography and video shoots. You can also create custom shipping labels to elevate the look of plain cardboard packaging.

3. Determine the Essential Product Information to Include

Decide Your Information Hierarchy 

List down all the product details that you want your buyers to read on your label. Afterward, arrange them according to importance with the product name and brand name on top. For instance, in a food product, your brand’s logo, product’s weight, and other graphics should go in front. Meanwhile, instructions, expiry date, company’s contact information, and others can appear at the back.

In the image below, the brand’s logo, which includes its brand name and tagline, is on top of the label. The product’s name appears just below the brand’s logo. Its ingredients are listed in a smaller font and occupy the lower half of the label. The product’s net weight and storage instructions are printed at the bottom of the label, in a much smaller-sized font.

Meanwhile, this product’s back-of-pack label includes directions on how to prepare its contents. The company’s contact information, its country of origin, and bar code also appear there.

Highlight Your Unique Selling Point

Why would a customer want to buy your product instead of another brand? Research and create a profile of your leading competitors. See what your competitive advantage is over them so you can incorporate it in your selling point.

You also need to know what your target market needs and wants. Run a survey using your social channels or email questionnaires. Find out what your consumers’ pain points are and how your brand can help overcome them. After analyzing their feedback, you’ll be able to go beyond enumerating your product’s features or what it can offer. You can tell your buyers how your product can meet their needs and wants.

Below, the brand cited the benefits of its iremia oil burner blend on its rear label.

Include Legally Required Content

Check what your national, local, and industry laws state about the mandatory information that a custom label should carry.

In the United States, the Federal Hazardous Substances Act requires household items like cosmetics, cleaning products, and art materials to have storage and safe handling instructions. Thus, custom labels should carry signal words such as “poison”, “caution”, or “danger” and steps for first-aid treatment.

Food and beverage manufacturers are required to disclose the nutritional value and ingredients used in their products on the packaging. According to an American Heart Association survey, a majority of food shoppers (59%) always read packaged food labels before buying the product for the first time. The U.S. Food and Drug Administration also expects manufacturers to list the allergens, additives, and other chemicals used. 

Many plastic and latex products, such as children’s toys with toy parts, should carry choking hazard warnings, according to the Consumer Safety Protection Commission.

Use Customer-Friendly Language

Again, knowing your target customers is important here. You can review social media comments and feedback to pick out the phrases they commonly use. Also, use the results of your surveys and questionnaires to know what words resonate with them.

Besides using easy-to-understand language, be honest about what your product contains. In the latest Innova Consumer Survey, transparency emerged as the top need among food shoppers. This means including the ingredients list in plain English, certifications, and in-depth nutritional information.

Provide Space for Your Barcode

Barcodes are now necessary in helping you keep track of your products, whether inside the warehouse or the store. Aside from shipping and inventory purposes, they also protect your products and brand from counterfeiters. You can also use barcodes for promotions to reward consumers and build loyalty.

4. Consider the Packaging Materials

There are several factors to think about when deciding on the type of material to use for your individually cut labels. The label material refers to the facestock or that which receives the printed text, image, and barcode.

Shipping Container Size and What It’s Made Of

Will you be sticking the label on cardboard boxes or glass, can, or plastic shipping containers? Does it have a solid color or is it transparent? And how large (or small) is it? You need to measure the surface onto which you will apply your label so you can get the right fit and pick the correct adhesive.

Printing and Finish

Pick a material that carries your preferred texture—matte or glossy—and can take the kind of coating or finish that you want it to have such as hot stamping, embossing, debossing, and others.

Environmental Factors

Your chosen material should stay durable throughout your product’s lifespan. What kind of environment will it be exposed to? UV light can fade out inks, while water exposure can cause the ink to smear or get washed off the label.

Products that are subject to extreme cold such as refrigerated food may need freezer-grade adhesives. Meanwhile, others that are exposed to heat, such as products you take with you outdoors, are prone to peel (label lift). Special equipment can remove condensation to prevent this problem or adhesives should be allowed to fully set 24 hours after application.

Some custom labels may need foam or tape to reduce friction, while labels placed on wearables may need skin-friendly applications to endure stretching and sweat.

5. Select Your Colors and Fonts

Amid the possibilities, it’s best to stick with your core brand colors to strengthen your brand’s identity and reduce the chance of counterfeiting. Also, it’s best to refer to the Pantone Matching System to determine how your brand colors will register on preferred label materials.

Color

Colors are typically associated with certain emotional or psychological responses:

• Green: Green symbolizes growth, a fresh start, health, nature, peace, and wealth. Its darker shades can imply wisdom and prosperity. It’s used by brands that are into organic food and pro-environment products. Some investment firms also use green as it stands for the color of money. Goes well with: blue, yellow.
• Blue: Like green, blue can evoke a sense of tranquility and openness. Many banks and communications firms use this color as it embodies intelligence, security, and reliability. It’s also found in many home cleaning products as it conveys a sense of tranquility and openness. Goes well with: green, yellow, red, and orange.
• Red: Red exudes excitement, warmth, and strength. Brighter shades can stand for high energy while burgundy, maroon, and darker shades can represent elegance. Many food and beverage brands include this color in their packaging. Goes well with: yellow, black, blue, white, and green.
• Orange: Orange also radiates vitality and a sense of adventure but by a notch or so lower than red. It’s also linked to confidence, creativity, friendliness, and innovation. Innovators, technology, sports, recreation, and home improvement brands carry this color. Goes well with: blue, black, and white.
• Yellow: Yellow stands for joy, clarity, optimism, and youth. It’s recommended for children’s products, bath and body items, candle brands, and honey distributors. But it’s also ideal for warning labels and products containing powerful chemicals. Goes well with: red, blue, and black.
• Purple: Purple suggests nobility, luxury, and ambition. It’s also associated with youth, creativity, and spirituality. Several creative startups have opted to use this color, and so have some beverage companies for their wine bottles. It’s also found on custom labels of some anti-aging and high-end skincare products. Goes well with: yellow, blue (when mixed with deep purple).
• Pink: Pink is the color of romance, softness, serenity, and fantasy. Many skincare and beauty business brands tap this color. Goes well with: blue (when combined with baby pink), black.
• Black: Black evokes power, sophistication, solemnity, or mystery. It’s a popular choice among liquor brands and candlemakers. Goes well with: white, yellow.
• White: White represents simplicity, cleanliness, and innocence. It can also stir up feelings of lightness or reverence for what’s supernatural or sacred. The color is a common preference among medicinal, health and beauty, and household brands. Goes well with nearly any color.
• Gray: Gray indicates neutrality, balance, and professionalism. Information and technology, architecture, and industrial circles favor this color. Goes well with: brown.
• Brown: Brown creates feelings of comfort and dependability. Organic products as well as tea, coffee, and chocolate brands include this in their brand colors. Goes well with: purple, gray.

As a general principle, the darker the hues, the more serious your message is compared to bright and fun shades.

Typography

Just like in color selection, the fonts you choose for your custom labels should resonate with your brand. There are mainly four basic types of fonts:

• Sans serif: These fonts don’t have “feet.” A few examples are Arial, Helvetica, Century Gothic, and Corbel.
• Serif: These traditional fonts have feet. Examples include Times New Roman, Garamond, Georgia, and Baskerville.
• Slab serif: Although not very popular, these fonts have thick and bold serifs like Rockwell, Memphis, and Soho.
• Script: Examples of these cursive or handwriting-like fonts are Freestyle Script, Lavanderia, and Yellowtail. The upper case of “Unreadable” script fonts like Precious and Shathika can be used as the first letters of paragraphs.
• Display: Inspired by handcrafted signs and calligraphy, display or decorative fonts are best used for headings instead of body copy. Algerian, Pinewood, and Monoton are examples of display fonts.

To ensure you pick the appropriate font for your product labels, it should:

• Reflect the qualities of your product and brand voice. You can select chunky and loud fonts for fun and affordable products. Meanwhile, clean, light, and delicate or formal-looking fonts are suitable for high-end products.
• Appeal to your target demographic
• Meet regulatory standards, clearly presenting product benefits and instructions
• Work well with your graphics

While you can choose between classic and more cursive fonts for your product names and front-of-the-package details, it’s best to use simple but legible fonts for the rest of the product information such as ingredients list and directions for use.

When you come across a font that you like while browsing the web, you can discover its name by using online font finder tools.

6. Use High-Resolution Images

When preparing artwork to use or submit to your label printing service provider, choose images with a resolution of at least 300 dots per inch. Avoid pulling images uploaded on a website as they’re usually low-resolution and will look blurred when printed.

7. Conduct a Test Survey

You can work with a market research firm to hold a label test survey so you can tweak or further customize its design or content, depending on the feedback, before launching a full custom label printing run.

Set Your Brand Apart with Stunning Custom Labels

The team of creatives at Refine Packaging can turn your design ideas into reality, creating beautiful customized labels that will delight your customers and build brand affinity, all at a reasonable price for your business.  

Contact us today for a free, no-obligation quote on your custom packaging needs. We’ll support you in creating personalized labels that convey your brand’s unique personality, have amazing social appeal, and protect your product no matter where it travels.

The post Custom Labels: Essential Guide on Types and Design for Printing appeared first on Refine Packaging.

Rigid packaging boxes are also referred to as set-up boxes as they’re usually displayed in stores along with the products they contain. They often hold high-end items such as electronics, jewelry, and cosmetics, so some people also call them luxury packaging.

Rigid packaging boxes normally consist of two parts: thick chipboard with a 36- to 120-point thickness (about 2-3 millimeters), which is 4x to 5x thicker than folding carton boxes, and the thinner and more flexible paper wrap that’s pasted over the chipboard to cover it. It’s the wrap that gets customized for branding and can feature foil stamping, varnish, coatings, and other premium printing techniques and textures.

Some custom rigid boxes also have lining interiors that add an elegant touch besides shielding products from scratches and dust. 

Comparing Rigid Boxes vs Folding Cartons vs Corrugated Boxes

Rigid set-up boxes are always in 3D form and generally don’t require assembly before they’re filled. Unlike carton boxes, rigid boxes typically can’t be folded to lay flat and reassembled into their box form, although some brands are now developing collapsible ones.

Due to their thickness, customized rigid boxes can withstand the stress of shipping without damage, protecting the usually fragile products they contain. However, rigid gift boxes may not be as tough as corrugated boxes, which are made of several dense paper layers. Corrugated boards are more versatile in that they’re lightweight and can be folded flat like carton boxes. They can also be customized, being the box of choice for stand-up, point-of-purchase, or point-of-service displays. 

Benefits of Using Rigid Boxes

What makes rigid gift boxes a great option for your business?

1. They’re Customizable

You can look into several possibilities when it comes to using a custom rigid box as part of your marketing strategy for luxury retail packaging or e-commerce packaging. Depending on your target buyers, you can choose a unique shape with a bright and fun design or a more conservative layout with little to no embellishments.

Chipboards come in different values of thickness, while you can play around with your logo and brand name on the wrap using specialty paper, printing techniques, coatings, and finishes.

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2. They Don’t Require Setup

Unless you opt for collapsible models, a customized rigid box doesn’t need assembly, so they reduce the labor involved once they’re delivered to your company.

3. They Raise Brand Awareness

Rigid boxes can help increase sales if you can pick a box style or design that stands out from your competitors. Boxes can feature a clear window, sticker labels, or a specific structure that delivers a pleasurable handling and unboxing experience.

4. They Improve User Experience

Quality packaging is important as it’s the next thing that consumers lay their eyes on after seeing or touching your merchandise. Custom packaging boxes can enhance the visual and tactile appeal of a product. This makes the item look elegant, increasing the worth of your brand.

Thus, rigid packaging boxes give prospective and current customers a well-rounded experience from the time they examine it (whether online or in a physical store) until they receive it via delivery or take it home after their in-store purchase.

5. They Can Boost Your Credibility

When the printing of your logo, brand name, artwork, and product details, plus the box’s finish, appear high quality, your brand appears more professional and trustworthy.

6. They Protect Against Damage

As their name suggests, rigid boxes are supposed to be sturdy enough to protect their contents from the effects of storage, handling, and long-distance travel. Their lids are meant to be secure, and the inserts can securely hug the items, including bottles of oil and tincture, so that they don’t arrive broken. Inside panels for sweets can also prolong shelf life.

7. They Can Be Repurposed

Due to their sturdy construction, many pieces of luxury packaging become keepsakes and are reused as drawer separators or storage containers, especially if they have quality magnetic closures or similar resealable lids. From mementos and jewelry to important documents and printed photos, well-designed, high-quality packaging boxes can become a part of one’s work desk or closet for a long time.

8. They Support Brand Loyalty

You can make your rigid packaging boxes reusable for other purposes: to build a following. Using eco-friendly materials is highly popular and can attract environmental advocates who are very particular about how packaging boxes are made. 

When Not to Use Rigid Packaging

Rigid boxes may not be the best option if:

1. You Have a Large Product

Although the structure of rigid setup boxes can offer superior product safety for small to medium items, its design may not be suitable for large home appliances as their heavy weight may put pressure on the edges. High-end corrugated packaging may be a more viable alternative.

2. You’re Not Yet Ready for a Large Expense

As you read on, you’ll discover that you have to pay more for rigid boxes due to more expensive and thicker materials, the more specialized process involved, and higher shipment fees.

If you’re not ready to invest in rigid packaging, you can ask your manufacturer how it can work with your design using a quality folding carton or high-end corrugated box.

3. You Have Limited Time

Rigid boxes take longer to produce than carton boxes, so you may have to go for carton boxes if you have a tight schedule. 

Different Types of Rigid Boxes

Rigid box packaging styles are either two-piece or hinged: 

1. Telescope or Top-Load Boxes

With Corners

The telescope box features a lid that covers the base midway (partial telescope) or nearly all the way to the bottom edge (full telescope). Some full telescope lids have thumb cuts or semi-circular cutouts, which make them easier to lift from the base.

The classic shoebox, which has a lip that is typically one inch deep, is an example of a partial telescope box. Many commercially available high-end gift boxes as well as our own windowless shirt boxes and luxury cosmetic packaging are structured this way. They can come in various shapes, too.

The neck or shoulder (others call it shouldered) box is another example of a partial telescope box. This type of box has a dual base, with the inner one (also called the tray or neck insert) higher than the other. The protruding part of the tray is called the neck while the top edge of the outer base is referred to as the shoulder. The lid rests on the shoulder. There are shoulder boxes with an extra-long neck, creating a gap between the lid and the base of the box.

Meanwhile, the drawer-style box is a variation of the full telescope box. Also referred to as a tray with a sleeve or the shell and slide. This type of box is like your traditional matchbox. It has a slipcase going over the base or “tray” of matches instead of a lid on top. They’re suitable for items that need to be laid down instead of upright to prevent damage or to preserve their contents. Such products include smartphones, jewelry, and some cosmetics.

Without Corners

Cylindrical rigid box styles, also referred to as rolled-edge tube packaging (or just tube packaging), feature either telescopic or shoulder-neck openings. They make a great packaging option for bottles, markers, other circular-shaped items, as well as powdered goods and irregular-shaped objects. Brands can also consider them alternatives to metal packaging.

Some rigid tube boxes have plastic or metal lids. Their interiors can feature plastic inserts (as in the case of beauty products) or foils.

2. Hinged Lid Boxes

With Cover on the Hinge

Hinged lid boxes have covers that are permanently attached to the base. They close due to their weight, via magnetic strip, or other securing material. The lids of some of these boxes, such as the flip-top or cigar box, don’t have a lip that covers the base of the box. The covers of the book-style box are the same as that of a cigar box—the covering flap extends slightly beyond the base so that when you close it, the box looks like a hardcover book.

Meanwhile, the clamshell design has a lip that goes down partially or down to the bottom edge of the base. In some hinged lid boxes, there’s a cloth or other lining that covers the hinge joint. 

No Cover on the Hinge

Custom Rigid Boxes: Different Types of Finish

Besides having versatile structures, rigid boxes can also offer you plenty of finishing types, from the way the wrap encompasses the box to the look and feel of the wrapping material.

Partial vs. Full Finish

When the wrap only covers the entire outer surface of the lid and tray, it’s called a partial finish rigid box. You can see the lips of the wrapping paper folded and glued to the chipboard’s interior, but most of the board is bare and visible.

Meanwhile, the chipboard is wrapped to its entirety in a full finish rigid box. The inner wrap may be colored white or another color.

Exterior Add-Ons

Brands can select from a variety of options when they want to go for fancy packaging.

1. Coatings 

Coating can come in different types:

• Varnish: Varnish is made of clear ink and creates a thin satin, matte, or glossy layer on the wrap. It can be applied to a specific area (spot varnish) or the entire sheet (flood varnish).
• Aqueous coating: A water-based coating gives your boxes a glossy or matte surface, making it easier to clean dirt and fingerprint marks off of them. They’re also scratch- or scuff-resistant and more eco friendly than varnish or ultraviolet (UV) coatings. Because this type of coating is food-safe, it’s usually preferred for boxes that house food and beverage.
• Ultraviolet coating: UV coatings need UV light or sun exposure to quickly harden coating. They offer the highest gloss finish, but foil stamping can’t be applied to them. UV-coated sheets can be embossed, but they should completely harden first.

2. Lamination

Lamination involves spreading polypropylene or a very thin, plastic film on the wrap, making it water-resistant and moisture-free. It reduces creases and small cracks. The higher level of protection it offers makes it pricier than varnish, which is why it’s mostly used for high-end luxury packaging. Most custom luxury boxes feature matte—as opposed to glossy—lamination. It’s the best coating to use when planning to add foil stamping, embossing, and spot UV on your outer design.

3. Hot Foil Stamping

Heat and pressure are used to apply foil designs of gold, silver, or other colors. The bright metallic foil can highlight your brand and logo.

4. Embossing and Debossing

Creating raised areas (embossing) and indentations (debossing) can enhance the texture of your high-end gift boxes and fancy packaging, making it more eye-catching and attractive to consumers. Embossing and debossing create depth when applied to foil-stamped material.

5. Flocking

Flocking is the method used in rigid boxes where there are velvet or suede-like textures on certain parts of or the whole wrap. The short fibers can be made of cotton, wool, rayon, or other synthetic materials. They can be dyed according to your color preference. This process may also be applied on the surface of some inserts.

Special equipment, as seen in the following video, electrically charges the flocking fibers—causing them to stand up—before spreading them over an adhesive-coated material. 

How Are Custom Rigid Boxes Made?

Brands and sellers tap rigid box manufacturers for luxury brand packaging or high-end retail packaging solutions. The creation process normally involves three stages:

1. Conceptualization

Contracting companies can tap the expertise of a rigid box packaging consultant to come up with the right design that will meet their goals. Some manufacturers also have an in-house design and engineering team that can handle conceptualization and prototyping.

At this stage, designers need to know the following points:

• If the item to be packaged is part of a broader product line, which has an existing design that should be followed or patterned after
• If the box will have to hold many items in a specific way
• If a certain artwork should appear in front of the box that may affect sizing specs
• If you want to incorporate advice from your retailer, who’ll ultimately decide which of your products will be put on sale at its store

Once the concept and budget estimates are presented, reviewed, and approved, the box maker can create the template. The contracting company needs to provide the artwork that will go on the wrap of the rigid box.

2. Production

Production is done by machine, hand, or a combination of the two. The wrap is printed beforehand, undergoing lamination or other treatments required by the client. On the other hand, chipboards are scored and cut to the correct size and shape. Machines (quad stayer) or staff—or a combination of both—then fold the tray or base of the rigid boxes and apply adhesives on the corners so that the sides stay up.

In packaging companies with fully automated systems, pre-trimmed wraps are trimmed and lined up in a conveyor belt. An arm places the tray on the glued surface of each wrap. Then the tray with the wrap beneath it passes through a plunger, which glues the wrap evenly on the tray’s outer surface.

3. Delivery

The packaging material itself also needs protection during shipment. This aspect should be considered and included during the design stage. 

Testing

About 11% of shipped goods arrive with damages. This results in the brand replacing the unit, offering a discount, spending on return freight, and missing profit. More importantly, customer trust is adversely affected when boxes—or worse, their contents—come with dents, scratches, or torn parts.

Thus, production of your custom rigid box packages and other high-end packaging will only be complete when testing is conducted.  

Dimension Testing

Even before your chipboard gets wrapped, it has to be tested for accurate dimensions. In an automated assembly line, the folded chipboard should have the precise length, height, and width or diameter to ensure that the wrap will cover it partially or fully, depending on the company’s design specifications. Meeting the prescribed measurements is also necessary to ensure that the product, inserts, and fillings will fit inside.

Label and sticker application is also set automatically in mechanized production. Thus, custom rigid boxes should all have the exact and accurate dimensions so that seals and any other adhesive-based matter will be placed on the right spot.

Drop Test

This allows contracting companies to determine how the box will stand up to accidental falls. The most popular drop test procedures come from the International Safe Transit Association (ISTA).

During the test, the product is placed inside the box and a machine drops the box on a hard surface from varying heights. The test can be performed on the corners, edges, or sides of the box. The manufacturer or supplier should analyze any resulting damage and work out a solution. When the improved box is available, the test is repeated.

Drop test machines for various package sizes and weights are available in the market. 

Common Custom Rigid Box Mistakes to Avoid

Using custom rigid boxes may turn to your disadvantage due to the following:

1. Use of Oversized Packaging

No matter how fancy the packaging is, buyers will be turned off if they discover a small product inside a big box. Disappointment over the false impression can lead to negative online reviews or even a lawsuit.

2. Lack of Differentiation

Your custom rigid boxes shouldn’t only be eye-catching but also distinct from those of your competitors. Be sure to research your segment thoroughly and get your design team’s opinion about how your product can stand out.

3. Insufficient Protection

Boxes for bottles containing liquids may need a grease barrier. Waterproof-coating should be considered for custom rigid boxes that will go on outdoor display.

4. Not Child-Friendly or Pet-Friendly

When you’re targeting adult clients of various ages, packaging should include instructions for human and pet parents. It should clearly state whether contents include choke hazards or hazardous substances. 

Factors That Contribute to High Prices

A custom rigid box can cost an average of $4 to $5 per piece, more expensive than a fully printed and labeled corrugated box (under $2 to $3) or a folding carton box (under $1). As the previous sections mentioned and indicate, the higher cost can result from:

Materials

More expensive chipboard, which is thicker than regular, foldable carton packaging, is used for custom rigid boxes. They come in a variety of colors—including white and black—with natural chipboard being the cheapest.

Your choice of paper and finish for the wrap also affects the final price. Full finish boxes cost more as they require more paper to cover the chipboard.

When it comes to finishes, metallic, neon, and other specialty inks are more expensive than regular ink. And naturally, larger surfaces will entail more materials. Any labels, magnetic strips, or ribbon pulls needed also add to the total expense.

Construction

The tooling cost in your final bill covers the use of custom-made tools needed to produce each custom rigid box, including dies for cutting its shape, foil stamping, and embossing or debossing, as well as print cylinders, print plates, and molds. The fee goes up if your packaging box has a unique shape or various parts and involves many colors and other printing techniques. Inserts require separate cutting dies and molds.

Reputable manufacturing companies use special machines to fold parts of your custom rigid boxes, paste their sides, and cover them with wrap. But manual labor may be required for intricate packaging or inclusion of inserts, which can be made of tissue, cardboard, foam, or plastic.

Volume

The packaging industry also follows economies of scale, so small-run custom packaging projects will cost more than large ones.

Transport

A majority of custom rigid boxes aren’t collapsible so they don’t ship flat, thus requiring higher shipment fees. Moreover, the rising cost of fuel will ultimately impact how much you have to pay couriers or third-party delivery firms.

Storage Space

As custom rigid boxes arrive pre-assembled in their final form, they need plenty of storage space. Ask your packaging company if it offers managed inventory service. This refers to keeping an agreed level of stock for you and shipping on a just-in-time basis or when you need them. You can also survey your business warehouse for any unused space.

Ways to Cut Rigid Box Production Costs

Here are some workarounds to consider when you need to deliver rigid boxes on a budget:

1. Opt for Standard Sizes and Thickness

A complicated structure will inevitably command a higher price. If this is beyond your budget at this time, use a standard size and thickness that will demand less customization from your manufacturing partner. Standard chipboards are easier for them to buy in bulk or may be available in their stock at a volume that can cover your custom rigid box order. This will result in lower costs for you, an early production start for them, and a faster turnaround time. 

2. Go for a Smaller Design

Want to stick with your original concept? Maybe you can reduce the graphics and shorten the text to make them fit in smaller cardboard packaging. You can also try repositioning the product in a different way or even disassembling it to see if a smaller box will work for you. One advantage of using smaller rigid boxes is that more of your products can fit on a store’s shelf at one time.

3. Pick Lighter Materials

Know your options when it comes to chipboard thickness. Then discuss with the design or manufacturing team how a thinner version can support your advertising and functional needs.

4. Choose Digital Printing for Low-Volume Runs

Although not as high-quality as offset printing, digital printing is more cost-effective, especially if you have a simple and minimalist design.

5. Tone Down Embellishments

• Consider adding a viewing window. A cut-out area that will show the product inside the box might be a cheaper alternative to embossing or foil stamping, especially if there’s artwork in the primary package—that is, the label on your product’s bottle, plastic casing, and so on.

• Reduce the area(s) where foil-stamping or embossing will be applied. The cost goes higher for every square inch where these treatments are used. Choose only the essential parts of your box for these finishes.

• Select water-based coatings and low-gloss finish. UV and glitter coatings are more expensive. A low- or semi-gloss finish can be a good alternative to lamination, which is known for high moisture protection.

6. Use Paper and Tissue Paper Inserts

These materials are more affordable than foam padding. Paperboard inserts with slits can provide the support your rigid setup boxes need for gadgets, cosmetics, luxury candles, and more.

7. Contact and Get Quotes from Different Suppliers

Ask three or four reputable packaging solutions companies to give you a quote, specifying your materials and size. Then determine which one can do the job at a more affordable price without sacrificing quality. 

What to Look for When Choosing a Rigid Box Maker

An ideal custom rigid box supplier should have the following characteristics:

1. Specializes in Rigid Box-Making

Folding carton manufacturers currently outnumber rigid packaging makers. Custom carton box makers may offer to do the job for you by outsourcing the work and just bill you for added costs. It’s better to choose a company whose specialty is rigid packaging. Ask for actual samples, not just prototypes.

2. Employs In-House Designers

It’s best to find a producer with a team that can help you come up with custom quality packaging that will best suit your product. This can help minimize delays and improve coordination as you only have to deal with one company from conceptualization to production.

3. Communicates Effectively

Check client reviews. Companies manufacturing rigid setup and luxury boxes with good reviews most likely listen well to what their clients need and want, resulting in a low error rate. They should be able to promptly answer your questions regarding how boxes are made, the minimum order size, and turnaround time, for example. They should also be able to provide practical solutions.

4. Respects Environmental Sustainability

Today’s consumers are drawn to brands that are conscious about environmental protection. A rigid setup boxes producer that’s Forest Stewardship Council-certified means that it uses paper products from responsibly managed forests. You can also choose custom product packaging manufacturers that use recycled fibers, practice water stewardship, and operate with renewable energy. 

Market Updates and Trends

The rise of work-from-home opportunities has recently paved the way for more people to shop online for various goods, including luxury and gift items. The demand for rigid paper packaging remains high despite the growing popularity of bioplastic, which may affect the quality of food and flavor of liquids and releases polluting methane gas.

The personal use and gifting of video games and equipment, confectionery, wine and other beverages, personal care items, bags, clothes, shoes, watches, and jewelry packaged in luxury rigid boxes, especially among millennial customers and Gen Zers, is expected to drive e-commerce growth in the coming years. The market for this box type will be worth more than $5.4 billion by 2030, according to forecasts. Custom two-piece rigid setup boxes will be at the forefront, with its value expected to reach $268 million until 2025.

Collapsible Rigid Boxes

As mentioned earlier, several manufacturers can now design and produce foldable rigid setup boxes. They can offer the versatility and convenience that custom carton boxes can offer, with the top selling point being their ability to store flat, which lowers shipping cost.

Smart Packaging

More and more brands will continue to integrate digital technology into their custom rigid boxes for better quality and customer engagement. Here are some examples:

Printed Electronics

Boxes with near-field communication (NFC) chips can provide more product information, prove authenticity, enable tamper detection, and even detect temperature when consumers bring their smartphone close to the NFC tag. Brands may also use NFC and radio-frequency identification (RFID) stickers to track orders.

Quality custom packaging may also feature LED and OLED lighting devices. These flat, nanometer-thin types of lighting can make your business logo, product name, or parts of the packaging glow or cause a holographic image to appear using hand pressure or with the aid of a smartphone, without the need of a battery.

Augmented Reality

Brands can include a QR code in the packaging that will allow buyers to view the product with animation and sound effects or play a mini-game, with virtual objects seemingly emerging from thin air. The visual appeal of AR-enabled packaging is reportedly two times stronger than regular ones.

Impress Your Customers with Luxurious Rigid Packaging Boxes

Refine Packaging is the top choice for the world’s Inc 5000 and Fortune 500 companies. With super fast production times, affordable pricing, and a sky’s the limit attitude, we’ll help you turn your custom packaging into a competitive differentiator. Contact us today and a dedicated packaging specialist will guide you through every step of the custom packaging process without breaking a sweat.

The post Rigid Boxes: A Complete Guide to Luxury Packaging appeared first on Refine Packaging.

Custom box inserts may be just what you’re looking for. 

Custom packaging inserts can be made from a variety of materials like cardboard, foam, and fungi. These stylish and practical inserts can be custom-sized to fit your unique products.  

You can use packaging inserts to ship all kinds of products. Want to give that bottle of wine a little added padding? Have a plant you need to send? A custom insert will hold them securely, so they arrive at the recipient safe and sound. Even large and heavy items can get added protection when nestled in a custom insert.

Custom inserts not only cradle your precious cargo, so they get to their destination in one piece. They can also give your packaging that wow factor. Custom inserts can take your customers’ unboxing experience from ho-hum to something they’re eager to share with friends word-of-mouth and the world through social media. 

So, let’s get started! Here’s everything you need to know about custom boxes and inserts. 

Types of Custom Inserts

There are items you can place in a box and send off without putting any thought into it.  However, you give your customers a lackluster experience when they open that box. 

Also, most products need some sort of added protection to ensure their safe arrival. This is where void fill options come in handy. Examples like packing peanuts, crinkle paper, PE foam, and air pillows protect your products and help boost their presentation. 

These are all great options for certain products and in certain situations. But sometimes, you want to add something a little extra to make your customers’ experience much more special.  

Enter custom packaging inserts. 

Custom inserts keep the cargo safe from damage during shipping as they fit the exact specifications of your products. More importantly, they add style to the packaging and help you achieve your branding goals. They’re also not limited to securing the actual products. You can use inserts as trays or dividers.

But what type of packaging insert is right for you? 

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First, you must choose what sort of material you must use for your custom inserts. Each material has its characteristics that add to the presentation of the product packaging. 

Also, coming up with the best custom packaging depends on the product you’re putting in the box. Each product requires different ways to keep it safe during delivery. You can’t just use any material for your packaging inset and expect the product to arrive at the destination without any damages.

According to studies, product damage is the cause of 34% of customer returns related to packaging. So, you can’t afford to lose more than a quarter of your sales due to negligence.

It’s also important to keep in mind the company vibe you want to reflect. If your company mission statement centers around sustainability and environmental causes, use eco-friendly materials for your packaging inserts. 

Last, your budget will also play a part in what type of insert you choose.

To give you a summary of the different kinds of custom boxes, below is a handy table for your reference:

Now, let’s take a look at common materials used for custom inserts: 

Paperboard Inserts

Not all inserts need to be heavy-duty. Sometimes products don’t need much protection, but you’d still like to have an appealing presentation.

Paperboard inserts won’t give you maximum protection, but they’re a great choice for carton boxes and invitation boxes. They’ll keep your products in place and add to an overall pleasing presentation.

Paper stock is also good for small, lightweight items, such as beauty products or stationery. These inserts usually come in natural kraft color or white. Finally, there’s plenty of opportunities to add your branding, such as colors, logo, and message, suitable as paperboards are easy to print on.

Corrugated Inserts

Another affordable option is corrugated cardboard inserts and boxes. They’re heavier duty than the paperboard inserts and offer more protection. You might see these used in a box to separate fragile items like bottles.  

As you can see in the below image, Fuego Box uses custom inserts to display their hot sauce bottles beautifully and to prevent the bottles from spilling into each other. No one wants to open a box to find glass shards and sauce strewn around.

As with the kraft paper inserts, you can also easily print on corrugated cardboard. So feel free to add a message or use a brand color.

Rigid Chipboard Inserts

Rigid chipboard inserts are made from reinforced cardboard, making them good for shipping and protecting fragile items like ornaments or perfume bottles.

They’re also great for keeping products separated, so they don’t rattle into each other.  And since the design is pretty solid, this type of divider might be reused by customers to store other items down the road. 

Foam Inserts

Foam inserts are best for protecting fragile items like glass, camera lenses, and jewelry from scratches and scuffs. 

This foam padding type is made up of pre-scored squares that you can simply take out to fit your product. Since it eliminates the need for die-cutting, it’s a more affordable option. At the same time, these inserts are also super-lightweight and help decrease your shipping costs.

If you have different size products or have a smaller budget, “pick and pluck foam,” is an alternative to the die-cut foam inserts.  

Pulp Packaging Inserts

Pulp packaging inserts can be used for fragile items because they offer a lot of protection. Molded pulp inserts are made from recyclable and biodegradable materials like cardboard, sugarcane, bamboo, and other natural fibers. A perfect example of this packaging insert type is an egg carton.

Pulp packaging is highly versatile and comes in different shapes or sizes. They can even support heavy items like wine bottles. When empty, you can stack these inserts on top of each other to help you save storage space.

Mushroom Packaging

If you want to go further on the sustainability front, packaging made with mushrooms is the way. This packaging can be molded to fit just about any product, from cosmetic to CBD.  

For example, Ecovative Design’s Mushroom Packaging can be grown in only seven days and made from hemp hurds and mycelium.

Their packaging is 100% biodegradable so that you won’t be adding to the overfilling landfills. And you can even add it to your home’s compost pile.  

Molded Plastic

This packaging type is made from natural or synthetic materials with a polymeric structure, making it easy to mold when softened. Common examples of molded plastic include soda bottles, lids of takeout coffee cups, and water bottles.

Molded plastics were popular back in the day due its durability and cost-effectiveness. However, its non-biodegradable nature makes it harmful to the environment. 

Out of the 8.3 billion tons of plastic created between 1950 and 2015, only 9% has been recycled. Its effect on marine life has been devastating. This is a large reason why people are more conscious about using less plastic as much as possible. 

Coming Up with the Structural Design

Custom packaging inserts mean they’re specially made to fit your products and beautifully reflect your company vibe.  However, ensuring you get the right fit and look will take a little work on your end.  

First, it’s essential to determine the exact dimensions of the products you want to place in the insert. If you have a somewhat regular-shaped item, like a candle, or something cube-shaped, simply measure and share its dimensions with the manufacturer.  

But how about for odd-shaped items like drills, cameras, or game controllers? They have all kinds of nooks and crannies that make it challenging to get precise measurements. If the opening is too big, the item will fall out. Too small and it won’t fit. The insert is supposed to cradle your item just right to keep it safe and attractively displayed.  

In some cases, you may need to send the physical product to the manufacturer to get the measurements right. From there, they can build the insert around the product.

Also, avoid over-engineering your custom insert. You want it to offer the protection your items need, but you don’t want to add unnecessary weight or bulk to your packaging.

On top of ensuring the right fit for your products, you must also consider the fulfillment side of things. Cardboard inserts are usually made and stored flat, then folded into shape, and placed in the box.  Someone or something (if you’re using automated machinery) must put the inserts in all of those custom boxes.

While fulfillment should be easy, common issues you may encounter include receiving the wrong package due to poor shipping management. Getting your inserts printed and shipped by a reliable fulfillment center is key to a hassle-free delivery.

Also, you don’t want to frustrate customers with their unboxing experience. Make sure that taking the items out of the insert is as easy as possible for customers. 

Also, consider how your customers will dispose of this packaging. Is it easy to break down? Easy to recycle? Most people don’t want to fill their trash cans with excess packaging. 

Custom Printing and other Design Elements

Inserts don’t have to be a drab brown color unless that’s the look you’re going for. In fact, your insert doesn’t have to match the outside of the mailer box. Feel free to give your customers a little surprise inside. 

You can pick a bold color, print your logo or catchphrase, or write a message to your customers like a simple “thank you.”

Here are three of the leading printing techniques for paperboard or corrugated material:

1. Flexographic printing (or Flexo): This process stamps a non-photo quality design onto the cardboard material.  Since it works well on smooth and rougher surfaces, it’s a good choice for printing on corrugated material. And it’s a good option for large quantities.
2. Digital Printing: This newer printing technology uses the CMYK ink spectrum, giving you a wide choice of colors. Digital printing prints the design line-by-line so you can get photo quality. This process is more cost-effective for small batches, and it has a quick turnaround.
3. Lithographic printing (or Litho): The design is printed onto a label, and then that layer is stuck onto the cardboard.  Litho printing can give a premium look to your packaging.  You can add things like foil details and emboss with this method.  Litho is a good choice for large quantities of premium packaging. 

You can also choose what kind of coating and lamination you’d like for your inserts. Do you want to go for a glossy look? Or maybe a matte finish is more in tune with your brand. 

Get as fancy or simple as you want. Just make sure it ties in with your overall branding goals to delight your customers. 

Benefits of Custom Inserts

As seen above, there are tons of options for custom inserts. It’s now a matter of planning for the right materials and design elements for your custom insert design.

The extra time and effort you may need to invest in coming up with a custom insert design can have big-time benefits.  

Let’s take a closer look at some of the advantages of going with custom box inserts: 

Robust Product Protection

The most important job of your packaging is to ensure your goods arrive in one piece.  

The last thing you want is for your customer to open a box and find out that the special wine glass or new camera lens is shattered into pieces.

It doesn’t matter how great your products are or how pretty your packaging presentation is. If your products arrive broken, your customers will not be happy. And this incident could create a bad lasting impression about your brand that could lead to lost revenue.

Custom inserts are designed to secure and protect your products inside the box that they’re shipped in. They’ll effectively secure your unique products, no matter their shape or size or how many they are.

Presentation

Custom inserts can give your packaging a polished look that customers will take notice of. They can present your items in a way that makes your products the focal point. 

A beautiful presentation can lead to immense marketing benefits. For example, unboxing videos are pretty popular nowadays. In fact, the time people have spent watching unboxing videos from their phones is equivalent to watching “Love Actually” more than 20 million times. And most of the time spent on these videos is about the packaging of the product.

Also, many influencers, and even your everyday customers, have taken to sharing pretty packages on social media channels, such as Instagram and Pinterest.

Finally, according to surveys, 72% of Americans agree that packaging can influence their purchasing decision. In the case of e-commerce and retail, looks matter.

Amplify Your Brand Recognition

Custom package inserts can help customers take notice of your brand. You can add your logo to the insert or use your brand colors. You can even keep branding to a minimum to achieve a raw and bare look.

No matter what style you choose, giving your customers a thoughtful, high-end experience through your packaging will make your brand more memorable and excite your customers.  

And why is building brand loyalty so important? Consider this:

• 43% of customers spend more money on brands they are loyal to. (Fundera)
• 94% of people said they’d be highly likely to recommend a brand they were emotionally engaged with. (Genler)
• 48% of consumers report that they are more likely to become loyal to a brand during the first purchase or experience. (G2)
• 50% of shoppers say they’re more likely to recommend a product with branded packaging. (BusinessLoad)

Custom packaging inserts are a great way to pump up customer loyalty. Not leveraging your packaging to get your brand noticed potentially leaves a lot of money on the table. 

The Environmental Angle

Environmental concerns are on top of the consumers’ minds, and this includes packaging.  No one wants to contribute to landfills or have a giant carbon footprint.

Recent research conducted about sustainability concludes the following:

• 74% of those surveyed would pay more for sustainable packaging, and nearly one-fourth are willing to pay for an increased cost of 10 percent or more.

• 60% of consumers say they are less likely to buy a product in harmful packaging.

The bottom line is that the friendlier your packaging is to the environment, the better.

Inserts made from paper or cardboard are not only easy to recycle but also sustainable. Look for manufacturers who use responsible forestry.

Want to go a step further? Try inserts made from organic material like fungi.  Not only are they super sustainable, but they’re even home compostable.  Who would have thought discarded packaging could help grow a garden?

A Few Potential Drawbacks

As with everything, there are some potential drawbacks to going with custom box inserts. Ironically, many of their cons are what make custom inserts so special. There are three main disadvantages:

• It’s a custom design: On one hand, custom design will make your brand stand out. On the other hand, unlike stock packaging, they’re going to take longer to complete. You can’t grab these inserts off the shelf or put your order in and expect the product the next day. 
• These inserts are product-specific: Sure, this means they’ll offer optimum protection and fit your products like a glove.  But, if you sell a bunch of different products, this may be problematic. Coming up with custom inserts for hundreds of unique products could prove to be a logistical nightmare.
• They’re more expensive than many other void-fill alternatives: As with all of your packaging needs, you need to keep your budget in mind.  Custom inserts might not fit your bottom line today, but they may be something to consider in the future. 

A Little Inspiration

The eCommerce industry generated an estimated $839 billion in sales last year, which increased over 40% from the year before. But there’s a lot of competition out there.  Everyone is trying to claw their way to the top.

So, what can you do to get your products noticed?

It’s going to take a little effort on your part to keep your current customers and attract new ones. Beautiful packaging, including custom inserts, is one way to do that.  

Let’s take a closer look at how some companies are using custom box inserts to enhance their customers’ experiences:

Warby Parker

Finding that perfect pair of eyeglasses that look just right on your face can be a real chore.  That’s why online prescription eyeglass retailer Warby Parker introduced a program where they’ll send out five free pairs of glasses. Decide which one (or ones) you’d like to keep and send the rest back.

Since glasses are fragile, they require extra care when mailing them out. Warby Parker uses a corrugated box with insert dividers to keep the glasses separated and ding-free.

Ritual Vitamins

Ritual is an online multivitamin retailer that developed itself into an Instagram darling.  So you know presentation is important to them including with their packaging.

In the above example, Ritual uses its signature bright yellow color for an eye-catching insert. This color is found splashed across their website, so including it in their packaging reinforces their brand identity. 

Cupcakes

Cupcakes aren’t just for little kids’ birthday parties anymore. In recent years, all kinds of boutique cupcake shops have sprung up across the country, lending these once humble little cakes an air of sophistication.

But nothing less unflattering than a smooshed cupcake. These delicate little cakes need protection. Custom inserts can ensure these tasty morsels make it home looking as good as they did on the bakery shelf. 

Winestyr 

More people are enjoying the ease of ordering their wine, especially since the pandemic. But can you imagine the mess a shattered wine bottle would unleash upon delivery? Talk about a way to lose customers fast! 

Winestyr is fully aware of this. As an online purveyor of artisanal wines, you can join their wine club or order premium gifts. Since their whole business is about shipping out their product to customers, they have their packaging dialed in.

In the above example, they have three wine bottles nestled in a cardboard insert. The insert both protects the bottles and nicely presents them.

Esquire Beast Box

Esquire needs no introduction, but its new subscription gift box does. Named “Beast Box,” it contains various men’s grooming products, in line with Esquire’s branding.

The box insert has different-sized sections for each of the products included. Also, the understated color scheme exudes masculinity, which is just what you’d expect from the brand.  

Pirells Innovative

Here’s a concept design from Pirells Innovative for a premium watch box. The monochrome color complements the simple yet elegant design. The pattern made on the mailer box and the inside insert are made by cutting the black paper, which gives it a unique, memorable look.

When you pop open this box and find a watch lying on the insert, the overall presentation oozes luxury and sophistication. 

Tait Design

You wouldn’t expect a design studio to skimp on presentation, and Tait Design does not disappoint. 

The hot pink cardboard box for their yo-yo matches the printing color on the outside of the box. It pulls the whole look together and makes a “child’s” toy feel unique and fancy.

Get People Talking with Memorable Custom Packaging Box Inserts

Custom box inserts can take your packaging from unremarkable to something that gets people talking. Packaging inserts are only one component of your overall marketing arsenal, but they can build trust, increase brand recognition, and enhance your customers’ overall experience. 

Custom box inserts will protect your goods and make them look good. They’re made from various materials, so you can find one that reflects your company’s values. What’s not to love?

Refine Packaging is the top choice for the world’s Inc 5000 and Fortune 500 companies. With super fast production times, affordable pricing, and a sky’s the limit attitude, we’ll help you turn your custom packaging into a competitive differentiator. Contact us today and a dedicated packaging specialist will guide you through every step of the custom packaging process without breaking a sweat.

The post Ultimate Guide to Custom Packaging Inserts appeared first on Refine Packaging.

A lot happens in the first few seconds after a package is delivered. When your customer first lays eyes on the box you’ve sent to them, you have an opportunity to trigger an emotional reaction. Play your cards right, and you can delight your customer, reinforce your message, and build brand affinity. Alternatively, if your packaging supplies and boxes aren’t up to scratch, your customer may feel frustrated, underwhelmed, and less likely to order from you again.

These days, it’s simply not enough to just deliver a package safely. Of course, this is of paramount importance, but it’s really the bare minimum and now expected. What’s needed today is customization. 

In the 2021 fiscal year, FedEx Express delivered an amazing 6.6 million packages each day. You may be an online shopper yourself. Just think back to the amount of packages you’ve ordered over the last few months. Chances are, the e-commerce packages that stood out from the crowd are the ones that were customized. 

This is because a premium look and feel, plus clever branding, has the power to build relationships between e-commerce brands and their customers. In the absence of physical stores and face-to-face customer service, your shipping boxes are more than just a safety measure; they’re a creative medium that can be harnessed for communications and marketing. 

Still not convinced? Think about the growing number of unboxing videos and posts on platforms like YouTube, Instagram, and TikTok. Then there’s the research by experts, which shows just how much consumers value thoughtful, customized packaging: 

• 72% of American consumers say their purchasing decision is influenced by the packaging design. (Ipsos)
• 61% say they are much more likely to repeat a purchase of a luxury product if it came in premium packaging. (Dotcom Distribution)
• 40% of consumers will share an image of your packaging on social media if it was unique or branded. (Dotcom Distribution)

Unboxing the Magic of Packaging with Custom Shipping Boxes

Leading e-commerce players are those who understand the magic of an end-to-end customer experience. Sure, you have a great website, but the customer’s retail experience isn’t over until your product is safely shipped into the hands of your customer. Factors like product quality, competitive prices, fast checkout and shipping, and a good online customer service team play an important role, but the unboxing experience is also crucial. 

In fact, a wondrous unboxing experience can be the difference between a one-off customer and a loyal brand advocate. While it’s tempting to keep costs as low as possible and go for the cheapest packaging options from a financial perspective, this doesn’t bode well with consumers.

According to GfK, consumers value brands with a premium look and feel. In fact, they’re more likely to buy less products that are higher-quality than more products that are of low quality. 

When your product arrives, the packaging instantly gives a first impression to your consumers. A plain cardboard box can look cheap and thoughtless, which is the opposite of the premium quality that today’s consumers crave. 

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On the other hand, when your products arrive in bespoke, carefully designed custom shipping boxes, you demonstrate to your customer that you’ve put thought into the shopping experience and care about your brand. 

Plus, your designs can go beyond just being eye-catching and pretty; they can tell your brand story. With the right typography and messaging, your custom shipping boxes can become another key vehicle in your marketing strategy. 

It’s clear that by customizing shipping boxes, brands can improve their relationships with customers and boost both marketing and sales efforts.

Is a Shipping Box Right for My Business? 

Of course, a shipping box isn’t the only way you can get your products to your customers. There are other options, too, like the mailing envelope.  

Mailers are a good choice for lightweight, robust items like clothing or jewelry that is already packaged in a gift box. You don’t need to pick between mailing envelopes and shipping boxes, though. Depending on the products you offer, you may choose to use a mailing envelope for smaller items and a shipping box for larger ones. 

To help you understand the pros and cons of each shipping container, we’ve created a handy table below that gets into the details. 

Mailing Envelopes vs Shipping Boxes

Once you’ve made up your mind between mailers and a shipping box, it’s time to move to the next stage. 

Types of Boxes and Box Style to Consider

You know you’d like to use custom shipping boxes to delight your customers. Now, it’s time to think about the type of box to go for. Generally speaking, there are six main kinds of custom shipping boxes, designed to accommodate different products. Take a look at the main types below. 

• Regular Slotted Container: Think of regular slotted containers as the traditional, common box. It’s likely that most of the packages you receive come in these types of boxes. This is because regular slotted containers are versatile, reliable, and come in a wide variety of sizes, making them ideal for a range of products. Regular slotted containers have a simple design, making them easy to manufacture with little waste.
• Full Overlap Container: A full overlap container is like the sister of the regular slotted container. The one main difference is that the flaps in a full overlap container overlap one another to completely cover the box’s width. This gives the box another layer of thickness, which provides more padding and safety. For products that are more fragile, the full overlap container is a great option. Again, it comes in many sizes. 
• Full Telescope Containers: Full telescope containers are an unusual shape. They’re usually the length of a telescope, which is where they get their name from. They’re made from two slotted regular banks that are placed together. This gives the box layered edges, making them sturdy and strong. The long, rectangular shape of full telescope containers makes them perfect for products like magazines, newspapers, and even artwork. The shape of these types of containers could be instrumental in making a brand statement. 
• Wraparound Blank: The wraparound blank is pretty much like a regular slotted container box but switched sideways. These custom boxes are usually used for rigid products that will fit snugly within the wraparound blank, making for a tight, protective fit. Wraparound blanks are typically packaged using a robotic machine, which is great from an efficiency and productivity standpoint. Usually, these custom shipping boxes are used for perishable products like food and wine, as well as home and personal care items.
• One-Piece Folder Box: The one-piece folder box is for items that are slim and shallow. This box uses one piece of cardboard, creating a smooth bottom. The flaps of this piece of the cardboard are used to create the top of the box, and also broken up into side flaps. One-piece folder boxes are easy to assemble, making them convenient for small businesses to use and store. They’re often used for shipping books, magazines, artworks, or picture frames.
• Five-Panel Folders: Five-panel folder boxes are made from corrugated box material. They are created using a single piece of cardboard that is divided into panels. The fifth of these panels is used as the closing flap, which functions to seal the box. Usually, these boxes are used to ship long, slim items like metal rails. Because of their unusual shape, they’re less likely to be used for e-commerce products.

Once you know the kinds of boxes out there, the next question is: How do you create an amazing custom shipping box strategy at the right price? Here are five things you need to know.

1. Size Matters

Before you can start customizing your bulk shipping boxes, you need to first think of the basics, starting with size. 

If your shipping box sizes aren’t right, not only will they cost more, but your items could end up being damaged if the box isn’t properly filled. Plus, it’s well-known that online shoppers hate waste. In fact, 88% of U.S. and U.K. consumers want brands to be environmentally friendly and use sustainable materials. So if your box is too big and overfilled with non-recyclable filling, your customers won’t be happy.

Not only that, but a too large or too small box demonstrates a lack of care and thought,  which relates back to the premium look and feel concept we mentioned earlier. If a customer’s first impression of your brand is that your custom shipping boxes are tatty and poorly packaged, you need to do a better job.

To decide what size box you need, assess the needs of your company, and take the time to analyze your products. The box you choose will need to tightly fit them inside but leave some room for padding to minimize the likelihood of product damage during handling, storage, and shipping. This will also help reduce shipping costs. Generally speaking, the smaller and lighter the box, the lower the cost of transport. 

As mentioned previously, if your products are small enough, then you may want to consider customized mailers. These sleekly designed packages do exactly what they say on the tin: They arrive in the mail. You’ll often see these kinds of packages used for subscription boxes. 

If your business needs a shipping service to move your products, then your next best bets are shipping cartons or cardboard shipping boxes, assuming that your products are not fragile or delicate. If this is the case, then the best choice is corrugated shipping boxes, which are more robust and sturdy. 

2. The Look and Feel

Once you’ve got the size and type of packaging figured out, it’s time to get to the fun part: design. A sense of style and flair for design can turn a plain rectangular box into a marketing superstar. 

Creating a customized shipping box goes beyond just graphics and colors. You can consider textures and finishing options, too. You want your box to best represent your brand and your products. Every choice you make has the potential to be a statement. 

The first thing to consider is the texture of your packaging. Depending on your brand values and colors, this could be anything from embossed gold to kraft-feel brown, or even a luxurious leather texture. When it comes to textures and the whole design process, this is an opportunity to let your creativity go wild. So choose the right material and create something spectacular that wows a variety of customer types. 

As an example, take a look at Earth Fare’s eye-catching customized packaging. The company’s eco-friendly packaging instantly conveys the brand’s values as a natural, ethical company.

However, you don’t have to stick with neutral cardboard brown. You can customize your boxes’ colors so that they are in line with brand guidelines. You can also decide if you want the color finish to be glossy or matte. It’s worth remembering that different colors and textures need to be carefully combined to make sure you get the look you want. We advise experimenting before you commit and order your custom shipping boxes in bulk. 

3. The Custom Box Design

We’ve already mentioned brand guidelines, and the design element of custom shipping boxes is where these come to the forefront. Your logo, typography, artwork, company strap-line, and more can come into play here. After all, customized shipping boxes are an excellent marketing vehicle. 

It’s likely that your social media pages and websites are exploding with your brand tone of voice, and it should be on your packaging, too. Your custom shipping boxes are a storytelling opportunity, a way to build affinity with customers. Tell them something they didn’t know about your company, and make them feel special. What you write—or don’t write—is important. 

Think about your brand and its values: Are you subtle and elegant, loud and proud, or colorful but modest? Once you’ve narrowed down a few words to define your brand, it’s time to think about how the design of your customized shipping box can reflect this.

For example, if your brand is eco-friendly and values minimalism, you may want to go for a crisp kraft paper with a small amount of lettering in a delicate typography. Alternatively, if your brand is exuberant and colorful, then you may want colored cardboard, decorated with different patterns. 

Keep in mind that small boxes have limited room. For example, if you’re a cosmetics brand and are only delivering a single product, it’s likely you’ll only need small boxes. However, this doesn’t mean you need to skimp on the design. Instead, think of how you can make the most of the space you have to make an impact. 

After you’ve got the design sorted, it’s time to think about printing options. The option you choose takes price into consideration, but it’s also worth thinking about the intricacy of your design. There are three main print methods to consider:       

• Flexographic/direct printing: This is perfect for high-quality printing of basic designs, featuring a maximum of three colors. This option is cost-effective and produces a beautiful, professional-looking finish in your custom shipping boxes. 
• Lithographic printing: This is great for more intricate designs or those that incorporate photography. Lithographic printing is often considered as the highest caliber in terms of quality, although it is more expensive, especially if you need a large quantity.  
• Digital printing: This is a more basic form of printing that can even be performed from home. It’s cheaper but also produces low-quality prints. If you’re on a budget or think your designs may change, then digital is a great option to start with. 

4. Customize Your Box From The Inside Out

You’ve mastered the exterior design of your custom shipping boxes and you’re sure it will wow your customers. Now, it’s time to think about how you can continue the wow factor once the box is opened. 

The inside of your shipping boxes are a continuation of your brand story. You can design the interior of your box just as you would the outside, with typography and brand colors that continue to tell your story. 

Aside from the box itself, think about the interiors that surround your product—the filing. While bubble wrap and styrofoam are traditional packaging cushions, they aren’t the most exciting or ingenious. However, with a little bit of thought and creativity, you can turn your packaging cushioning into another tactic in your customization strategy.

For example, if you use packing peanuts, you could consider changing the color and shape so that they represent your brand. Alternatively, you could consider using colored tissue paper to add a sense of luxury to the unboxing experience. 

Aside from cushioning, it’s a good idea to think about how else you can make the unboxing experience YouTube-worthy. If you’re a small company, you could perhaps include personalized, handwritten notes to make your customers feel special and show the care that goes into packaging your products. Details like stickers, newsletters, ribbons, and free samples are also a great way to make the unboxing experience feel even more rewarding for your customer. 

5. Outside the Box

When it comes to sealing your custom boxes, there are two main kinds of tape to consider. There’s water-activated tape and pressure-sensitive tape. 

• Water-activated tape is a type of paper tape that incorporates a water-based chemical. When you put the tape on the carton, a chemical reaction is triggered, which strongly bonds the tape to the box. This makes water-activated tape extremely strong and almost tamper-proof. It’s also great for keeping products safe in even the roughest conditions, as the tape’s bonding measures mean it’s difficult for water to get into the box. 
• Pressure-sensitive tape, by comparison, uses a sticky adhesive substance, which sticks to the box when it’s rolled on. This is the kind of tape you’ll be familiar with in everyday life; it’s used in sellotape and masking tape, for example. Pressure-sensitive tape isn’t as strong and robust as water-activated tape. However, for small items and small businesses, it is good enough to do the trick, especially if your items are durable. 

Finally, after all the work you’ve put into creating amazing custom boxes, you should tell the world about them. Display your beautiful boxes with promotional products in them on social media, and share posts from customers who do, too. Ultimately, your customized shipping boxes can become another part of your content marketing strategy, helping you attract new customers and ensure your current ones keep returning. 

Logistics, Logistics, Logistics

A custom shipping box strategy doesn’t start and end with the box. There’s the whole process of getting your beautiful packaging in the hands of your happy customer. In the world of e-commerce, your price strategy for shipments can be a competitive differentiator. 

Free shipping, same-day shipping, and next-day shipping are all huge plusses. However, your choices need to make financial sense. If your model isn’t profitable, then this could cause long-term damage to your business’s revenue stream. 

Here’s an overview of the most common shipping methods for your custom shipping boxes, and how they could work for your company. 

Free Shipping

Did you know that 90% of consumers would increase their online shopping spending if they could select free shipping? However, while shipping may be free to the end consumer, it won’t be free for your business. There will always be costs involved.

Free shipping can be a viable option for many companies though. It’s all about the tactics you employ to strike a balance. For example, you could make the prices of your products more expensive to account for the cost of free shipping. Alternatively, you could strategically add the cost of free shipping into your financial planning and deduct it from your revenue. 

There are other options, too. Rather than offering free shipping across the board, you could run special sales, such as during the summer or Black Friday, in which free shipping is advertised for a short time. Another tactic is to offer free shipping for orders over a certain price. 

Charge Up-to-Date Carrier Rates

A more straightforward method is to align your shipping prices with real-time rates from suppliers like FedEx and USPS. If you’re savvy, you could even offer your customers a range of choices from different suppliers, enabling them to choose the option that works best for them. 

Some may wish to go for the cheaper option that takes a little longer to deliver. Other customers may want their product as soon as possible and so are willing to pay a little more for quick delivery. This transparency and the power of choice can go a long way toward making happy customers. 

Charge a Flat Rate

Another popular choice is what’s known as flat rate shipping. This is where you select a standard rate for shipping. Often, the rate is cheaper for a few days delivery and more expensive if the customer chooses next-day delivery. Flat rate delivery puts you in control and can be helpful from a financial planning sense, as you won’t have to incur the cost of free delivery. 

That said, flat rate shipping doesn’t take into account fluctuations in dimensional pricing, so if your products vary greatly in size, it could be a risky option.

Offer Pickup Options 

Another option to consider is offering pick-up delivery options, either curbside, store, or locker deliveries. This option can be viewed as more sustainable by end consumers, as it drops a number of parcels often at a central delivery point rather than delivering them to individual addresses. 

However, pickup options are often less convenient for the customer, unless the pickup spot is right down the road from their office or home. For this reason, we recommend offering pickup options in addition to one of the strategies above. 

Keep Your Products Memorable and Secure with Custom Shipping Boxes

You may be thinking, “This all sounds great, but where can I get customized shipping boxes?” Don’t fret because you’re in the right place. At Refine Packaging, our bread and butter is helping brands create customized packaging for all kinds of products. 

We understand that designing custom size shipping boxes in bulk can be a daunting, overwhelming task, which is why our friendly, experienced team is on hand to make the entire production process smooth, rewarding, and simple. 

Our team of creatives can turn your design ideas into reality, creating beautiful cardboard printed boxes that will delight your customers and build brand affinity, all at a reasonable price for your business.  

Contact us today for a free, no-obligation quote on your custom shipping box needs. We’ll support you in creating custom shipping boxes that convey your brand’s unique personality, have amazing social appeal, and protect your product no matter where it travels.

The post The Ultimate Guide to Custom Shipping Boxes appeared first on Refine Packaging.

That’s right—shopping bags! And specifically, the customized ones. While you may have your digital advertising efforts down, many companies are forgetting the power of traditional, subliminal promotion. Eye-catching, colorful custom paper bags with your branding and logo can draw in new customers, boost brand recognition, and even improve your revenue. 

The Business Benefits of Custom Shopping Bags

The benefits of custom shopping bags go beyond just marketing and advertising, particularly if you use paper. Recently, renowned luxury department store Harrods announced its plans to replace all of its plastic carrier bags with fully recyclable paper bags by the fall. The paper bags will be 100% recycled and also partly made from recycled materials.

The reason for the change, according to news analysis, is a commitment to sustainability, both from a corporate social responsibility standpoint and due to rising consumer demand. For more and more physical retailers, plastic just isn’t cool anymore. Its impact on the environment is hard to ignore, and as consumers become more aware about the dangers of plastic, they are looking to brands to help them make more eco-friendly choices.

As the below stats from IPSOS show, paper leads the way:

• 93% of consumers agree that paper is sustainable and should be used more as packaging.
• 86% of consumers agree that if they can choose between paper packaging or another material, they choose paper.
• 79% of consumers believe that paper is more pleasant to handle and touch.

Paper shopping bags don’t just look more eco-friendly, either—the science backs it up. A study from the IVL Swedish Environmental Research Institute looked into the greenhouse gas emissions produced by paper and plastic bags. It found that paper bags had a remarkably lower impact on the climate than LDPE (low density polyethylene) bags.

In the US, states are catching on to the downsides of plastic bags. California, Connecticut, Delaware, Hawaii, and Maine, just to name a few, have all brought in bans on single-use plastic shopping bags. 

So more customers want paper, states are mandating it, and scientists are recommending it. All in all, it seems that using custom paper bags is a no-brainer. But where to begin? That’s exactly what we’ll help you with below. 

Why Should You Use Paper Shopping Bags?

Before we dive into the what and how of a customized paper bag packaging strategy, we first want to nail the why. Being confident that paper grocery bags are right for your business and understanding how they can help you create a lasting impression is essential to making an informed choice. Here are some of the most common reasons why custom paper bags are a business asset: 

1. Sustainable 

We’ve touched on this above but we’ll say it again: Paper bags are an excellent eco-friendly packaging option. They are made from wood—a raw, renewable resource—and can be recycled. Consumers are also acutely aware that paper bags are better for the environment. This means that by choosing to use paper gift bags, shopping bags, and grocery bags, you’re not only looking after the planet, but you’re also showing your customers that you care, something they will no doubt appreciate! 

2. Versatile

As you’ll find out below, paper bags are definitely not one size fits all. Different sizes, shapes, colors, handles—the possibilities are endless. If you want to tell your brand story through custom packaging, then paper is an excellent and inexpensive option. 

3. Free Marketing

Have you ever wandered around a shopping mall when a colorful shopping bag caught your eye? Maybe seeing the brand’s bag made you determined to find their store and go inside, or you remembered the name and brand colors. Either way, a well-designed paper shopping bag can boost brand affinity and lead to new customers. Plus, because paper bags are reusable, your customers may take them out again and again. Meaning, hundreds of people could learn about your brand, thanks to just a few bags! 

4. Cost-Effective

Facebook ads that point to relevant product pages on your website, SEO (search engine optimization), and Instagram influencer marketing can put a big dent on your marketing budgets in an instant. While these have a role to play in modern advertising strategies, we can’t forget the power of the in-person shopping experience. Personalized paper shopping bags are relatively cheap to create via bulk orders and offer limitless marketing potential. 

5. Tell Your Brand’s Story 

A paper bag is kind of like a blank canvas. Your team gets to decide what to put on it: the story you want to tell, the colors, the fine details. These bags offer a chance to unleash your creativity and make your company memorable to everyone who uses and sees your branded paper bags. 

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Custom Printed Paper Bags: The Basics 

At this point, we hope you feel excited about the potential of harnessing custom paper bags for your retail strategy. As you look for the right printed paper bags for your company, it’s important to remember the basics. Your paper bag needs to be as functional as it is fun. So it needs to: 

• Provide enough space to safely carry the volume of purchases by customers. You may need to consider offering different sized bags if your products vary greatly in size 
• Be strong enough to hold the weight of goods
• Provide customizable options that enable you to convey your brand’s story and values 
• Ideally, support environmental efforts and be in line with your company’s sustainability commitments 

8 Types of Paper Bags

So now it’s time to jump into the eight most common types of paper bags out there. There’s no such thing as a wrong or a right bag. The type of bag you choose will depend on the kind of products you sell, as well as the customer you’re trying to appeal to.

For example, some of the bags below are better for small items, while others are better for adding a touch of luxury to the in-store experience. Remember, too, that all of these bags can be customized so that they are unique to your company.

1. SOS Bag

The SOS bag is the iconic brown bag used for kids’ lunches. You often see it in cartoons—a generic, brown paper with edges that you fold over. The SOS bag can also come with small handles. Typically, it’s used for food and drink items but can also be used for small items like skincare or jewelry. While the bag is known for its natural brown kraft color, it can also be customized and designed in different shades and finishes. 

2. Pinch-Bottom Bags

The pinch bottom bag gets its name from the tapered bottom. It’s usually used for bakery goods and other food items. It has an envelope-like opening and is grease-resistant inside, which is why it’s favored by food stalls and coffee houses. It’s also suitable for takeaway bags.  

3. Merchandise Bags

Merchandise bags are probably the most common type of paper shopping bag you’ll see out and about. They come in a variety of styles and sizes, making them an excellent vehicle for customization.  

4. Euro Tote

The Euro tote is a step up from the SOS bag. This paper bag is heavily associated with luxury. These bags tend to be highly customized, down to the look and feel of the handles. When designed well, Euro totes can be their own form of gift packaging and go a long way to boost brand recognition.  

5. Bakery Bags

Bakery bags are designed specifically for the food market. They feature wax linings to preserve food items, making them a great option for muffins, bread, pastries, and more.  

6. Mailing Bags

Mailing bags get a sneaky mention on this list. Even though they’re more a form of ecommerce packaging, they do have “bag” in the name and are made from paper, too. Mailing bags are padded mailers. They’re great for shipping small items to customers who have purchased online. For a deep dive into padded mailers and other e-commerce options, check out this article about ecommerce packaging. 

7. Recycled Bags

While all paper bags are recyclable, not all paper bags are recycled. By this, we mean that not all paper bags are made from material that has already been used. However, you can specifically pick at least partially recycled paper bags. Doing this is great for the environment and is something you can shout about to your consumers who, as we’ve seen above, appreciate when brands choose paper-based packaging. 

8. Vogue Bags

Vogue bags ooze luxury and theater. These bags are more than just a paper bag; they’re an experience. With tissue paper, freebies, handwritten cards, and more to be usually found inside, these designer paper bags are a great way to make your clients feel like a million bucks. 

Common Types of Handles

Paper bags are about more than just the bags themselves; the handles play a huge role, too. There are a variety of customizable options, ranging in price and look and feel. Take a look at some of the most frequently used options below. 

1. Ribbon 

Ribbons are pretty, glossy, and add a touch of luxury to paper bags. They are also easily customizable. They can come in almost any color and suit most of the bag types mentioned above. Ribbons are quite durable but would not be appropriate for really heavy items, as they may snap. 

2. Cotton

Cotton has a similar look and feel to ribbon. It also portrays a sense of luxury, finesse, and is easily customizable. The main difference between cotton and ribbon is cotton’s durability. Cotton is a dense, strong material, meaning it can carry heavier products than ribbon.

3. Twisted Paper

Twisted paper handles are a cheap and cheerful option. While they aren’t as premium as cotton or ribbon, they are cost-effective and also very strong. They can endure a heavy weight and are extremely easy and quick to produce for manufacturers.

4. Folded Paper

Folded  paper is another cost-effective option. These handles are made from a piece of paper, making them great for lightweight purchases and small bags. However, be warned, folded paper bags tear easily if the weight of the bag gets too heavy. These handles also tend to disintegrate in heavy rain. 

Let’s Get Bespoke! 

Once you’ve chosen the type of paper bag you want and the coordinating handle, it’s time to think about customization. This stage is an opportunity to let your creativity shine and turn your visions into reality. No idea is too bold or whacky. Custom paper gift bags are a blank canvas that’s perfect for your art! 

In terms of cost, it’s important to note that the size of your bags directly correlates with the price. Depending on what kind of products you sell, you may want to order a few different sizes of bags. Similarly, the cost is strongly dictated by the amount of bags you order. How many stores you have will dictate the number of bags you need. You can choose to buy paper bags wholesale and keep them in warehousing facilities. Alternatively, you may want to put in a repeat request for your customized bags each month. 

1. Color Your Bag Beautifully 

You can choose any color, or colors, for your bag. Aside from colors, you can add colored features, like stripes, your logos, artwork flowers, and more. You’ll notice that a couple of acronyms pop up again and again when you’re looking at designs: RGB and CMYK. RGB stands for red, green, and blue. These colors are used for images on your computer screen. CMYK stands for cyan, magenta, yellow, and key (Black). If your design contains three or less colors, then RGB will be adequate. But if your design is more complex, then CMYK is the option you should go for.

2. Carefully Choose the Type of Paper

There’s more than one kind of paper that you can use for your bag. Paper varies in strength and thickness. The stronger the paper, the better it is for heavy products. However, if you sell lightweight products like jewelry, small gift items, and other accessories, then you may want a lighter paper option. Here are the main types: 

• Kraft paper: Kraft paper is what’s used for SOS bags. It has a natural, eco-friendly feel and is cost-effective. Kraft paper is best used for small to medium-sized items.
• Recycled paper: Recycled paper comes from 100% recycled paper, making it a great choice for eco-conscious brands. Recycled paper is also very versatile and varies in thickness, making it suitable for all types of products. 
• Art paper: Art paper is derived from wood pulp. As the name suggests, art paper is ideal for creating designs because it has a smooth texture. Like recycled paper, art paper comes in varying thicknesses. Art paper also varies in terms of textures.  

3. To Laminate or Not to Laminate?

Lamination is a process where a thick layer of plastic is applied to your paper bags, giving them an enhanced finish and improving durability. There are different types of lamination finishes, which we’ve put in the handy table below:

4. Finishing Touches

The outside of your bag is now looking beautiful, but what about the inside? To truly delight your customers, you want the personalization journey to continue once they open your paper bag, too. Most paper bags are white or brown on the inside. You could, for example, print your brand’s logo or slogan on the inside of the bag to enhance brand visibility. Alternatively, you could use embossing or debossing to add a touch of luxury to the inside of your bag. 

Another option is spot UV varnish, which can be used to create glossy, elegant patterns inside your bag. Also, you should consider how you put your logo on your bag. For example, foil stamping is often used to create attention-grabbing, bold statements, a la Urban Decay below. Similarly, embossing and debossing can be used on the outside of the bag for eye-catching designs.  

The Future Is Paper

So, that’s it—our ultimate guide to custom paper bags. As you can see, it’s clear that paper has a lot to offer to your retail strategies. Just as cardboard is leading the way in ecommerce, paper is fast proving itself as the go-to option for physical stores. Through design and customization, you can elevate your printed paper bags so that they become a marketing vehicle, one that enhances customer loyalty, boosts revenue, and increases brand awareness.  

Here at Refine Packaging, we’re experts in helping brands of all shapes and sizes to create customized packaging strategies that bring an ROI. Whatever your vision is, our experts are on hand to help you turn it into reality, at a price that’s right for your business.

Ready to embark on your custom paper bag strategy? 

Refine Packaging is the top choice for the world’s Inc 5000 and Fortune 500 companies. With super fast production times, affordable pricing, and a sky’s the limit attitude, we’ll help you turn your custom packaging into a competitive differentiator. Contact us today and a dedicated packaging specialist will guide you through every step of the custom packaging process without breaking a sweat.

The post The Ultimate Guide to Custom Paper Bags appeared first on Refine Packaging.

These not-so-humble box mailers are not only durable (to keep your products safe), but they’re also highly customizable, so you can get your brand noticed and create memorable experiences for your customers.  

Mailer Boxes: Shipping Essentials for Ecommerce

In retail, mailer boxes can be used as gift boxes and for sending out promotional materials. They are easy to assemble and extremely effective for keeping ecommerce orders safe and secure. Mailer boxes are nothing new, but they’ve become more mainstream because of the thriving subscription box market. 

Subscription boxes, as we know them today, have only been around since 2004, but they are now a dominant feature of the ecommerce landscape. Consider this:

• Fuel by McKinsey estimates the total market size of the subscription ecommerce market is about $12 billion to $15 billion.
• A survey by Clutch found that 54% of online shoppers are subscription box service members.

Many of the products subscription services are shipping out arrive in mailer boxes. These boxes, usually custom mailers, are very versatile, so they can fit all kinds of items. Everything from razors and makeup, to video game accessories and dog treats, can be ordered through a subscription box service. All of these items can fit neatly and be attractively displayed in a mailer box.

Mailer boxes aren’t limited to subscription services. They’re commonly used to send out everything from books and business cards to jackets and computer keyboards. In other words, if you order things online, you’ve likely seen a mailer box. 

All of this translates to a tremendous amount of boxes arriving on people’s doorsteps. 

Let’s find out how you can get the most from mailer boxes and stand out from the competition. 

Building Your Brand with Mailer Boxes

Not so long ago, companies and their customers gave little thought to what kind of box their products were shipped in. They just wanted the item inside to arrive intact and to be what they expected. But times have changed. A company that ignores what their mailer boxes look like is missing out on a highly effective and lucrative marketing strategy. 

Sure, ordering online is convenient, but often, customers are looking for more. They want to be wowed by the complete experience, including the shipping mailer boxes their goods arrive in. 

Mailer boxes offer so much room for customization. Even if your company is just starting out, you can give your customers a special experience. Everyone from tiny Etsy stores to well-established brick-and-mortar stores use mailer boxes for shipping their products and increasing brand recognition.  

Mailer boxes offer a lot of flexibility. You can:

• Come up with a unique design that promotes your brand. 
• Make use of your logo, slogan, and brand colors.  

Remember to stay consistent with your branding across all of your marketing channels. Think about what colors you’re using on your website or what type of font you’ve used for your logo. You want people to see the mailer box and immediately identify it with your brand.   

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Social Media and Unboxing Videos

Nowadays, social media is a key component of any marketing campaign, and unboxing videos are examples of initiatives that can skyrocket the value of your brand.

If you think people aren’t watching someone else open a box, think again. Try a cursory search on YouTube for unboxing videos, and you’ll be surprised at how many videos pop up. These videos are strangely addictive and popular.  

What is the first thing people see in an unboxing video? You guessed it – the box! You don’t want to skimp on your mailer box design and miss the opportunity to create that valuable first impression.

Two of the most influential YouTube unboxing channels are Ryan’s World with 28 million subscribers and Unbox Therapy with nearly 18 million subscribers. That’s a crazy amount of people tuning in to see someone else open a box. 

Sure, people tune in to these channels to see the actual products being unveiled, but they’re also enjoying the accompanying excitement of unwrapping the layers of packaging. 

If you want to get noticed by customers (or influencers), the overall presentation is important–and yes, that includes the box! A beautiful custom mailer can enhance your customers’ experience and even give your products a higher perceived value. 

What to Look for in a Mailer Box

Now that we’ve established the branding importance of mailer boxes, let’s talk about what makes up mailer boxes. As with all custom packaging, you want your boxes to be top quality. 

Here are some things you should consider when buying mailer boxes:

1. Paper Grades

Mailer boxes are primarily used to mail items and therefore durability is a must. That’s the reason why these boxes are usually made of corrugated material. It’s important to pick the right manufacturing paper for your purpose and products. 

Here are some common paper grade options for mailer boxes:

Kraft Corrugated Cardboard

These are the basic brown corrugated mailers we’re all familiar with. Kraft cardboard is an affordable option that gives you a rustic, natural look. Corrugated mailer boxes are made up of between 60-100% recycled material. 

Uncoated White Corrugated Cardboard

Some people prefer white corrugated mailer boxes. The look is cleaner, and graphics will stand out more with this choice. White corrugated packaging boxes also look high-end.

Clay-Coated Corrugated Cardboard

This corrugated packaging option gives you a smoother, brighter surface. It’s a little more expensive, so it’s a good pick for luxury brands.

Corrugated cardboard boxes also come in different thicknesses. Think about what you’re mailing. Is it lightweight? Fragile? Then decide on the flute grade (thickness) you need. Some common box mailer flute grades are E-flute 1/16 and B-flute 1/8.

Any kind of box can be dressed up or down, depending on your budget and the aesthetic you’re going for. A small budget is not an excuse to be boring. A simple brown box printed with your logo can create a lasting impression. 

Even if your budget is almost non-existent, you can customize your mailer boxes. Order a hand stamp with your logo or try a custom sticker. It’s all about making your boxes your own and reinforcing your brand. 

2. Closures

All of these boxes should be easy to assemble and need to be securely closed up somehow. Unlike regular shipping boxes that are often closed up with packaging tape, mailer boxes have some sort of tab-locking mechanism.  

Some mailer boxes come with additional protective dust flaps to keep dirt out. You can even choose a box with a tear strip for added security. If you’re mailing the box, you can further secure it with tape or hot melt glue, so it doesn’t pop open during shipping. 

3. Printing

You want your custom mailer box to create a good first impression as soon as it hits your customer’s doorstep. This means you want your text and graphics to look crisp and high-quality. Unintended blurry images are a no-go.

How good your graphics look comes down to the printing process you choose. There are several options out there, and there are a few factors to consider, namely your budget, any time constraints, the quality you’re looking for, and whether you are using your mailer boxes for shipping or retail packaging.  

You no doubt realize the important role colors play in evoking a certain mood or increasing brand recognition, so it’s vital to understand a little bit about how these colors are printed on boxes. 

There are two main color processes used when printing on mailer boxes: PMS and CMYK.

Pantone Matching System (PMS) 

PMS uses premixed ink formulas from Pantone, so you’re sure to get consistent colors across all types of mediums. With PMS, you get more vibrant colors. It is the best option if you’re using a lot of thin lines or metallic or fluorescent colors.  

If you’re using three colors or less, PMS is the cheaper option. But that doesn’t limit you to only three colors. You can “tint” colors to save money. For example,  if you’re using green, you can add a little white to come up with mint green.  

CMYK

CMYK is the other color option. It’s made up of four colors: (C) cyan, (M) magenta, (Y) yellow, and (K) black. This process creates the images out of tiny dots. It’s your best bet if you want to use full-color photos or need a lot of different colors. 

Now, on to the actual printing. There are two main options for printing on your custom mailer boxes: direct printing and pre-printing.  

Direct printing, sometimes called post-printing, is when you print directly on the box. This method is often used with corrugated boxes. 

• Flexography (or flexo) is a popular option. With flexo, you’re printing directly on the box. Flexo is affordable, has good printing speeds, can be quickly set up, and works well on both rough or smooth materials. Flexo uses PMS colors, so if you’re looking for full-quality photo images, you might not get the results you want.
• Digital printing is a printing method that’s gaining in popularity. It gives you higher quality than flexo. It’s fast but best for low volumes.
• Offset lithography (or litho) falls under the pre-printing category. It’s usually used for printing on custom labels, which are then glued to the box. This option is great for higher-quality photos or if you want to add some embossing or foil stamping. Litho labels can cover the whole box or just a small section. It’s up to you. 
• Foil stamping (or hot stamping) will give you an elegant, sophisticated look. Foil stamping is a printing technique that uses hot dyes to press a metallic print and foil onto the surface of the box. You can use a variety of colors, but a popular option keeps it simple – a black background with gold or silver foil. Foil stamping is usually found on the outside of the box. But why limit yourself? If you want something a little different, try it on the inside of the box.  

Keep in mind that these printing techniques aren’t mutually exclusive. Feel free to mix things up to grab your customers’ attention. 

If you want to get extra fancy, you can even combine direct printing with a litho label. Or if you want to splurge, go with two-sided printing. Whatever you choose, try to get the highest quality that’s within your budget. You don’t want to skimp on the appearance of your mailer boxes. You want them to look sharp and stand out. 

4. Finishes

Beautiful printing can be eye-catching and stand on its own. But if you want to elevate your product packaging design even more, consider adding a coating or other finishing touches. They can give your box a polished, high-end look.

Aqueous Finish

One popular and relatively affordable coating option is an AQ finish. This vegetable cellulose coating was introduced in the 1970s. The coating makes a box look shiny and smooth and protects it from smudges and scratches. You can opt for a glossy or matte finish – or even satin, which is somewhere in between.  

Another benefit of an AQ finish is it’s eco-friendly. Since it’s water-based, it’s nontoxic and can be easily recycled. 

UV Coating

This is a clear liquid coating that’s applied and then dried with ultraviolet light. This coating will give your box some added texture. You may want to opt for a spot UV varnish where it’s only applied to a specific area of the box. This is a great way to make a desired design element pop, such as your logo or slogan.  

To recap, here’s a table of the features and qualities to look for in mailer boxes:

Keep Your Custom Mailer Box Eco-Friendly

There’s no denying that e-commerce is booming. LimeLoop compiled data from the major shippers (USPS, FedEx, and UPS) and estimated that around 165 billion packages are shipped in the U.S. each year. But with all of these online sales comes huge amounts of waste heading to our already overflowing landfills.

This is concerning to customers and businesses alike. You can’t go a day without hearing distressing news stories about climate change or other impending environmental disasters. Sure, consumers love to buy the latest and greatest, but they’re also concerned about the environmental impact of their purchases. 

One study found that 74% of consumers were willing to pay more for sustainable packaging, and a quarter of these were willing to pay an increased cost of 10% or more. 

There’s no way to get rid of packaging completely, but customers appreciate companies that make an effort to be less wasteful. So give customers what they want. Box mailers not only look good, but they’re also one of the more eco-friendly options for packaging. 

Here are some reasons why:

• Most mailer boxes are made from post-consumer recycled materials.  
• Mailer boxes can be recycled again and again. They’re easy to break down, which encourages people to make an effort to put them in a recycling bin. According to the EPA, in 2018, approximately 32.1 million tons of corrugated boxes were recycled, which was a 96.5% recycling rate for corrugated cardboard boxes. That’s keeping a lot of packaging out of our landfills.
• Mailer boxes are easy to ship. They’re relatively lightweight and stack neatly in a truck, so it takes fewer trips to get them to their destination. Additionally, they’re usually shipped flat to retailers, which saves considerable space.
• Mailer boxes are usually made of corrugated cardboard materials, which biodegrade much faster than other shipping materials. Plastic, for example, can take upwards of 500 years to biodegrade. Embracing eco-friendliness isn’t lost on consumers. In a survey by consumer research firm Toluna, 66% of respondents said that paper or cardboard packaging is better for the environment.
• Retail and shipping mailer boxes are mostly made from materials sourced from sustainably managed forests. Look for companies that have FSC (Forest Stewardship Council) or SFI (Sustainable Forestry Initiative) certification for their corrugated mailers.
• Mailer boxes are sturdy enough to repurpose. You could use beautifully colored mailer boxes to store old postcards and other small mementos.

Eco-friendly doesn’t have to mean dull and monotonous. Sure, simply adorned kraft mailer boxes may convey the look you’re going for, but if you want to add more zing, there are many options. Today, you can find water-based, soy-based, and even algae-based inks that look beautiful and are good for the environment. So don’t let environmental concerns limit your color palette. 

Mailer Box Design: Be Sure You Get What You Want

With so many options for your custom mailer boxes, you want to get exactly what you want. No matter if you work with a designer or decide to go it alone, you want to make sure your mailer box design will fit your needs.

Are small mailing boxes the right size for your products? Make sure you can fit all of your goods comfortably. You don’t want a fit that’s too tight or to have your items swimming around in there. How about the graphics? Are the colors right?  Do your custom mailers with logo look good? Is everything spelled correctly?

When ordering custom mailer boxes, make sure to check the final proof. You can look at an online proof with a flat view, or perhaps a 3D mockup will help you visualize the final product. If you’re ordering a lot of mailer boxes and you have time, you may want to order a physical sample, so you know exactly what you’re getting.

Your shipping mailer boxes are the face of your business, so make sure you get everything just right the first time. You’d hate to order 1,000 boxes with your company name misspelled or the wrong URL emblazoned on the side. 

What Goes Inside Your Box

Mailer boxes are durable, but that doesn’t mean you can simply toss your items in and throw the box in the mail. There are certain things you may want to include inside.

Let’s start with protecting your product during shipping and fulfillment. Some items will fit perfectly snugly in the box and not need added padding, but for many items, you’ll need some sort of void fill to cushion your product so it’s not rattling around inside. 

Here are some common options for void fill:

• Packaging paper. This is an excellent way to fill space and protect your items. You can wrap individual items or ball the paper up to cushion your goods. Packaging paper looks decent and is recyclable.
• Crinkle paper. You’re probably familiar with the basic kraft crinkle paper. Color options are almost limitless. 
• Tissue paper. This is a simple, affordable option that can elevate the look of your packaging. It’s not the best for fragile items but works well for items like clothing.
• Cardboard inserts. Custom-designed inserts will protect moderately fragile items. Inserts are made to fit a particular item, so it’s best to use them on the products they were made for. 
• Foam cushions. If you’re shipping something fragile, this will help protect your items from scratches and breakage. You can cut the foam to shape to make it more useful. One big drawback is this type of cushion is not environmentally friendly. 
• Air pillows. These aren’t the most beautiful, but they’re lightweight, easy to store, and get the job done. 

In addition to protecting your products, throwing a few added goodies into your mailer box can make the experience more personal for your customers. That’s something most will appreciate. According to one study, consumers were 80% more likely to make a purchase when companies offer personalized experiences.  

So don’t waste the opportunity. It doesn’t take much to make your customer feel special.  Here are a few things you could include in your box mailers:

• Enclose a personalized thank you note. Or if you haven’t printed anything on the inside of a box, write “thank you” inside the top of the box. 
• If possible, use your customer’s name. In an Accenture survey, 56% of respondents said they were more likely to shop in-store or online at a retailer that recognized them by name.
• Toss in some coupons. People love discounts.
• Include small samples for other products. Your customer will feel pampered and special, and it’s a great way to introduce them to some of your other products.
• Add little toys, candies, or stickers. If you’re going for sophistication, this may not be the look you’re envisioning, but sometimes, a little frivolity is appreciated.
• Encourage your customers to share their experiences on their social media channels. Put your social media handles on the box with a hashtag you’d like to see trending. 

As with all marketing endeavors, presentation counts with mailer boxes. Of course, you need to work within your budget, but that shouldn’t stop you from adding a little something extra. Who knows? You might get lucky and a social influencer may share an unboxing video of your product.  

Perhaps more likely, customers will spread their impressions through word of mouth.  According to the American Marketing Association, almost 75% of consumers identify word of mouth as a key influencer in their purchasing decisions. And what better way to get them talking than getting them excited about your beautiful packaging? 

Corrugated Mailers in Action: A Little Inspiration

Having a lot of options is usually a good thing, but it can also feel overwhelming.  Sometimes, it helps to look at what others are doing. 

Here are some mailer box examples that will get your creative juices flowing and give you a good jumping-off point to come up with your own mailer box design:

1. Lily and Onyx

Lily and Onyx curates locally and internationally crafted goods that promote things like mindfulness and the “California” lifestyle. Their mailer boxes stay on brand. You can see the above packaging uses simple, tasteful, soothing colors, and typography that reflect the boho vibe the company is going for.  

As with their products, Lily and Onyx’s packaging has a natural look. You won’t find any wasteful packaging here.  

2. Love With Food

Love With Food, a snack delivery service, proves you don’t have to send out high-end goods to use stylish mailer boxes. Their service starts at just $7.99 a month, but they don’t skimp on their boxes. Their custom mailer boxes are bright red with white lettering, which reflects the branding on their website. The simple but bold color combination is sure to grab attention.  

3. Vegancuts

Sometimes, simplicity is the perfect reflection of your brand. Vegancuts offers snack, makeup, and beauty boxes. All of their offerings are 100% vegan and cruelty-free. They’re not about unnecessary excess, which is beautifully reflected in the simple line drawings and script on their printed mailer boxes. 

4. FabFitFun

Simplicity is not the name of the game for everyone. Popular lifestyle box subscription service FabFitFun is all about living life to the fullest. Their custom mailers are anything but subdued. Each season, they send out a new box with a new design. The boxes vary by the season, but they usually use several colors with images that cover the box inside and out. 

5. greenUP Box

What would you expect from a subscription box dedicated to reducing waste and plastics? Probably exactly what greenUP Box is sending out. Not only are their products all eco-friendly, but so is their packaging material.  

The leaf-covered design and earthy green color of the box are reminiscent of nature. The box and the crinkle paper inside can be easily recycled, so no waste here.

6. American Influencer Beauty Bundle

Sometimes, it’s all about the glam factor. American Influencer Beauty Bundle is a bi-monthly subscription service that gives customers exclusive access to influencer beauty products. Their shiny mailer boxes have a luxurious look that appeals to their customer base looking for the latest beauty trends. 

7. Smartass & Sass

As their name suggests, Smartass & Sass is all about “snark, sass, and sarcasm.” Their custom-printed mailer boxes might not appeal to everyone, but they reflect the company vibe and cater to their customer base. Spend a few seconds on their website and you just know this is a fun company with a certain brand of humor. 

Smartass & Sass uses boxes that look bold but are quite simple. It has kept the box for their secondary packaging to a single bright blue color with their name and a geometric pattern on top. They put their website address on one side and their catchphrase, “classy, sassy, and a bit smartassy,” emblazoned on another. Inside, they kept it plain to keep the emphasis on the quirky products you’ll find in the box.  

Every month has a different theme, so you never know exactly what you’ll get, which adds to the excitement. They even share unboxing videos on their website of past boxes, so you get an idea of what kind of experience you can expect when this box lands on your porch.

Put the Spotlight on Your Brand With Mailer Boxes

You’ve got a desirable product, so don’t leave your packaging decisions as an afterthought. Packaging should be a critical part of your marketing plan. It’s often the first thing your customer sees, so you want to get it right and make a great first impression. Think about what your company represents, and make sure your packaging reflects that.

A thoughtfully designed mailer box can up your game and boost your brand identity – and, in turn, increase your sales. Remember, customers are looking for the whole experience, so make your mailer box memorable and special. A quality mailer box can both ensure your goods get to your customers in one piece and – just as importantly – have them coming back for more.  

Refine Packaging is the top choice for the world’s Inc 5000 and Fortune 500 companies. With super fast production times, affordable pricing, and a sky’s the limit attitude, we’ll help you turn your custom packaging into a competitive differentiator. Contact us today and a dedicated packaging specialist will guide you through every step of the custom packaging process without breaking a sweat.

The post The Ultimate Guide to Mailer Boxes appeared first on Refine Packaging.

I’m sitting at my office desk and I currently see six. And no, I’m not a hoarder. All of my office supplies and printing paper were shipped in these boxes and can be neatly stored away in them, too.

Even in my home, there’s almost always a few corrugated boxes hanging out in the corner of my room or closet. I’m forever trying to clear out stuff and these boxes are where I put items for donation. 

The particular box that’s near me now came from Trader Joe’s, which used to box up my groceries. Initially, Trader Joe’s received a shipment of frozen hash browns in this same box. As you can see, a single corrugated box can serve many purposes and is rarely single-use. 

You probably take corrugated boxes for granted, but they play an integral role in our business and home life. 

Corrugated boxes are ubiquitous in our homes and workplaces – whether you work in an office, a garage, a retail establishment, a restaurant, a fire station – or pretty much anywhere.  

Most products are shipped in corrugated boxes and many products remain in these boxes for convenient storage. Many retail packaging boxes serve multiple functions before they work their way to the recycling plant. 

It’s no wonder that the corrugated packaging industry is booming. And with an increasing ecommerce demand, coupled with consumers desiring more eco-friendly packaging options, it’s not looking to slow down anytime soon. Consider these stats:

• It’s estimated that the U.S. shipment volume of corrugated packaging will be around 443 billion square feet in 2023.
• The corrugated board packaging market was valued at over $262 billion in 2019, and is expected to reach nearly $400 billion by 2025.
• More than 95% of all goods consumed in North America are packaged and transported in corrugated packaging.

• There are over 1,100 corrugated manufacturing facilities in the U.S.

Corrugated boxes offer protection, are cost-effective, and can easily be customizable.  

What’s not to love?  

Deconstructing the Corrugated Box in Packaging

Most people refer to corrugated boxes as cardboard boxes, but they’re technically not the same.  

This can lead to some confusion with the terms. Cardboard is a heavy-duty paper stock, commonly used for folding cartons and other applications. 

You’ll find folding carton boxes lining grocery shelves are often made of cardboard. Think of a cereal or mac and cheese box. This type of box is not one you would expect to survive the shipping process. Toss one of these in the mail and they’ll likely arrive at their destination in tatters. 

A corrugated box, on the other hand, is all about strength.  

Corrugated boxes are made up of a liner and a medium. These sheets of paper are glued together. They’re typically made of three fiberboard layers, but can be even thicker. 

The outer layer is called the linerboard or simply the liner. Liners are the flat material usually found on the outside of the board, but sometimes inside like in the case of a double or triple wall. 

The medium is the wavy layer in the middle, which is called a flute. This inside player is what gives corrugated packaging boxes their strength and why they’re so commonly used for shipping and storage.  

What Process Goes into Making Corrugated Shipping Boxes?

I’ll go out on a limb and assume that we all know that corrugated boxes start their life as a tree. That aside, let’s take a closer look at how these boxes are manufactured. Here’s an abridged look at the corrugated box process: 

• The trees are cut down and bark stripped off.
• These logs are ground into wood chips.
• The woodchips are pulped using a chemical (sulfite and sulfate) or a mechanical (grinding) pulping process.
• A corrugated rolling machine makes the fluting.
• A corrugator machine presses and glues the layers of boards together.
• A die cutter cuts out features like flaps and scores creases.
• The board is cut and glued.
• And voila, you have a corrugated box. 

If you want to delve even deeper and see the corrugated box making process in action, YouTube has a surprising amount of interesting videos of what goes into making corrugated boxes.

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Corrugated Boxes: It All Starts With Paper

There are two main types of paper used for corrugated boxes – kraft and test. 

Typically test paper is used for the inner liner and kraft paper for the outer liner of the box. 

Kraft paper is more expensive than test paper, but is higher quality.  

Kraft paper is made from softwood trees, such as Pine, Spruce, and Fir, and consists of 70-80% virgin chemical pulp fiber. It comes in several different versions, such as brown, white, mottled, fully bleached, and birch faced.  

Kraft paper also has a smoother finish, which makes for better printability. It’s also more water-resistant, which affords added protection to the goods inside. And because of its higher tear and burst resistance, it’s stronger than test paper. 

Test liners are usually made from hardwood trees that have short fibers, such as Oak, Sycamore, Birch or Chestnut, or recycled paper. Test paper is less expensive than kraft, but it’s less durable and harder to print on. That’s why test paper is often relegated to the inside of boxes, so it’s not as visible.  

Get to Know the Different Flute Grades for Your Corrugated Boxes

The flute (the wavy part sandwiched between the liner) is what sets corrugated boxes apart from their cardboard cousin. 

The flute size determines the thickness of the box walls and gives the box its stacking strength. Flutes are referred to by a letter that designates its size. They are measured by thickness and how many flutes per linear foot. Here are the most common flute sizes:

• A-Flute (33 flutes per linear foot) is the largest flute at 1/4” thick. Its thickness offers lots of protection and makes it a good option for fragile items.
• B-Flute (47 flutes per linear foot) is 1/8” thick. This is a lot thinner than A-flutes, but it’s deceptively strong.  It’s often used for counter displays or canned goods. This flute is popular for die-cut designs.
• C-Flute (39 flutes per linear foot) is 3/16” thick. This is the one you’re probably the most familiar with, since it’s the most popular option for shipping boxes.
• E-Flute (90 flutes per linear foot) is only 1/16” thick, so it’s pretty thin. It doesn’t offer the strength of the larger flutes but does have some advantages. It’s sometimes used instead of paperboard for folding carton boxes. It’s efficient to store and is good for printing.
• F-Flute (125 flutes per linear foot) is 1/32” thick and is among the thinnest of the flute grades. It has a very smooth surface, so printed graphics will look sharp. 

Picking the Right Wall Type for Custom Corrugated Boxes

Even if you know what flute size you want, you still have some important decisions to make. 

Corrugated packaging comes in all types of wall thicknesses. Sometimes you only need a little protection for your products, while other times you want something heavy-duty. Here are your wall type options: 

• Single-face: This is usually sold in rolls and is a single sheet of liner attached to one sheet of corrugated medium. It offers extra cushioning for delicate items. You might use this for added protection if you’re shipping something like wine glasses.
• Single-wall: This is one sheet of corrugated medium glued between two sheets of the liner. It’s the most common and is probably what springs to mind when you think of a corrugated cardboard box.
• Double-wall: This is more durable but less flexible.
• Triple-wall: This is the strongest, with three stacked corrugated sheets and four liner board facings. It’s used for industrial parts or sometimes for produce bins. 

Different Packaging Styles of Corrugated Boxes

Another important component when picking the appropriate corrugated packaging box for your products is finding the right fit. 

Corrugated boxes come in all shapes and sizes. You don’t want to have to cram your items, but you don’t want them swimming around either. 

When selecting a box size, keep in mind that the internal dimensions of a box are written as length x width x height (L x W x H).

Here are some of the most common box style options to choose from that come in varying sizes: 

• Regular Slotted Container (RSC):  This one is the most common. Think of your classic shipping box. With this box, all of the flaps are the same length, with the two outer length flaps meeting in the middle when the box is closed. You need tape to secure the flaps.

• Full Overlap Container (FOL): This type of box has added strength since both sets of outer flaps fully overlap, making it double-layered on the top and bottom of the box. 

• One Piece Folder (OPF): If you’ve ever ordered a book or other media materials, you’ve seen one of these boxes. They’re creased and slotted, then folded into a box. 

• Full Telescope Design (FTD): As the name suggests, this box has a separate top and bottom that fit over each other. The double walls give it extra strength.

Of course, these boxes need to be closed up somehow. Most commonly, corrugated boxes are closed up with packaging tape, tuck-in flaps, or strapping for heavy-duty loads. 

All of these choices can feel overwhelming, but there are many tools and services available to get you started on your quest for that perfect box. If you’re looking for a simple box, you can easily find a standard box template online.  

When you need something more complicated, with features like full 3D models or designing your die-cut templates, there are some sophisticated software options, such as ArtiosCAD, Impact, or Packmage. 

If you’re still unsure where to begin, request a free consultation with our packaging team for guidance about dielines, box styles, varnish and more that’s specific to your unique needs.

The (Many) Benefits of Corrugated Boxes for Shipping and Packaging

Boxes can be made out of all kinds of different materials, such as plastic, wood, metal, or paperboard, but there’s a reason corrugated boxes are such a popular option. 

Let’s take a closer look at some of the benefits of this type of box: 

Unrivaled Protection for Transportation and Shipping Safety

If your goods are being shipped in a corrugated box there’s a good chance they’ll arrive safely at their destination. 

Corrugated boxes can protect even the most fragile items, including glass and chemical liquids. The tear-resistant qualities of corrugated cardboard are hard to beat and they have the added advantage of guarding against moisture, so food items are kept fresh. 

The durability of corrugated boxes are one reason why so many companies use them as a staple of their shipping and fulfillment strategies.

Corrugated Boxes are Cost-Effective

The bottom line is important to all businesses. No one wants to waste money – especially on practical necessities.  

Corrugated boxes are relatively low cost to manufacture. Most of the time, custom boxes cost less than you might expect. 

Also, because they’re lightweight and can be easily stored, you can save money on storage and transportation costs.

Options for Custom Corrugated Boxes and Endless 

Corrugated box options are almost limitless. 

You can choose from all types of boards, weights, adhesives, coatings, treatments, flame resistance, static control – the list goes on. 

These packaging boxes can also be folded into all kinds of different shapes and box sizes. And we haven’t even touched on the exhaustive graphic design options corrugated boxes afford. 

There are all kinds of printing options so you can make your corrugated boxes unique to your brand.  

Corrugated Packaging Boxes are Environmentally-Friendly

Corrugated cardboard material looks like it fits the bill for consumers’ thirst to do right by the environment. Accenture recently surveyed 6,000 consumers in 11 countries and found the following:

• 83% of respondents thought it was important or extremely important for companies to design products that could be reused or recycled.
• 77% thought plastic was the least environmentally friendly type of packaging.
• But the good news for corrugated boxes, 55% thought paper products were the best option for the environment. 

Let’s look at some of the reasons, corrugated boxes get high marks for protecting the environment:

Corrugated boxes are easy to recycle

You have no excuses. In most places, you can just break down your boxes and put them in your curbside pick-up.  

• According to the EPA, in 2018, around 32.1 million tons of corrugated boxes were recycled out of 33.9 million tons of total paper and paperboard recycling.
• That year the recycling rate for corrugated boxes was 96.5 percent. 

Corrugated cardboard boxes are renewable

Corrugated packaging is made from a high percentage of recycled material (mostly in the 70-100% range). It can be manufactured from paper pulp that comes from fast-growing pine trees, or made from wood chips and other leftover materials.

Most corrugated box manufacturers get their paper from sustainable forests. No reputable paper company is going to be clear-cutting old-growth forests.  

Nope, quite the opposite.  

After all, it’s in the interest of paper companies to keep their supply going, so they’ll take actions like replacing harvested trees with seedlings. 

Corrugated shipping boxes are reusable

Corrugated boxes are easily collapsible, so you can break them down and store them in the garage until you need one for your next move or another future use.  

Corrugated packaging boxes save energy

Since corrugated boxes are mostly made using recycled materials, it takes less energy to produce them.  

Most are made without dyes and bleaches, so that’s one less step in the production cycle. They’re also relatively light so you can save on transportation costs.

Corrugated boxes are efficient  

A corrugated box offers a lot of protection so you don’t need it to be giant-sized or filled with excessive padding inside. 

Additionally, corrugated cardboard boxes are easy to stack or collapse when not in use – so you don’t need as much space to store them.

Drawbacks of Corrugated Boxes for Shipping and Packaging

Corrugated boxes can handle many of your packaging needs, but alas, as we all know – nothing’s perfect. As with anything, there are a few drawbacks: 

• A corrugated box, on its own, is not waterproof, so it’s not the best protection for the elements. If you leave a corrugated box in the rain it will eventually become a soggy mess.
• Both an unprinted or printed corrugated box does not have the strength of other materials, such as metal, so it might not be the best option for very heavy items.
• Sideways pressure may cause the corrugated cardboard to become deformed.
• It’s difficult for a corrugated box to maintain a pristine look. Because of its somewhat rough surface, even a box adorned with beautiful graphics may end up looking a little wrinkled and worn.  

But no matter your business, corrugated boxes will likely play a role in your custom packaging or supply chain needs. 

Testing Standards for Corrugated Packaging Boxes

Of course, if you’ve gone to the trouble of researching what flute grade and wall type you need – you understandably want some sort of assurance that the box will do what it’s supposed to do. And ultimately, that means protecting the products inside the box. 

Merchants, shippers, and consumers want to know they can count on the box to keep its contents safe. No one wants to receive a mangled box full of broken items at the end of a journey. 

Fortunately, corrugated boxes go through a rigorous testing process. 

There are several tests, with the two main tests used today being the Edge Crush Test (ECT) and the Bursting (Mullen) Test. 

These tests are important since most transportation companies, such as UPS, FedEx, airlines, and railways require shipping boxes to meet certain standards.

Here are four commons testing methods to consider for your corrugated cardboard boxes:

• The Edge Crush Test (ECT) measures the stacking strength of the box, which will let you know things like pallet shipping durability. ECT is a laboratory test method where the edge of the board is compressed between two plates. It’s measured in pounds per linear inch and is used to calculate the maximum compression force a box can withstand.
• The Bursting (Mullen) Test measures the force needed to rupture or puncture the corrugated cardboard. This test gives you an idea of how well a box will protect the goods inside during shipping.
• A Flat Crush Test measures the resistance of corrugated paperboard to flute crushing. This will help you determine how much pressure you can safely apply to your box during the printing process, whether you choose digital or offset printing.
• A Water Absorption Test (COBB) measures how much water corrugated fiberboard absorbs over a specified time under standardized conditions.  

Box Maker’s Certificate (BMC) 

These test results aren’t hidden away in a lab notebook somewhere.  

Nope, the results are often right in front of you. 

You’ve probably seen a circular stamp on the bottom of many corrugated boxes. 

Maybe you haven’t given it much thought, but that little stamp is chock full of information. It’s called a Box Makers’ Certificate (BMC) and has been widely used since around 1968, when the trucking and rail industry started relying on them.  

Today, this stamp is found on the bottom flaps of many corrugated boxes. 

Let’s take a look at what information you will find on a BMC:

• The name of the manufacturer and where the box was manufactured. This information is found in the outer ring of the circular stamp.
• Something along the lines of, “This Singlewall box meets all construction requirements of applicable freight classification.”
• The bursting test information (lbs. per sq. inch), or edge crush test information (lbs. per inch).
• The size limit (often given in inches).
• The gross weight the box can support. (Keep in mind this is the very upper limit.  It’s best to leave a little cushion.)

A Box Makers’ Certificate (BMC) doesn’t guarantee the box will protect the goods inside, since it doesn’t take into consideration things like moisture resistance, and of course you are responsible for any necessary padding inside.  

But, it’s a good starting point. At least you’ll know it’s not a good idea to cram a heavy barbell into a box only rated for ten pounds. 

In addition to the BMC, you may find other stamps on a corrugated box – depending on what is being shipped.  

Glassware, hazardous materials, and food often require additional stamps.  And many corrugated box manufacturers like to advertise their environmental credibility – so you might see stamps like “recyclable” or “sustainable forests” on the bottom of some boxes.

Don’t Settle for Dull Corrugated Boxes: Add Excitement to Your Packaging Design

What comes to many people’s minds when they hear the term corrugated box is a drab, brown rectangular-shaped box.  

Sure, this classic type of box serves a huge purpose, but corrugated boxes don’t have to be merely functional. They can also be used to enhance the unboxing experience and to pump up brand recognition. 

Don’t limit yourself to a boring shipping box; add some pizzazz.  

Why not take advantage of the advertising space? 

Go on and plaster your company name or logo on your custom boxes or seal them up with some custom packing tape. It’s easy enough to change up the look of your boxes, so you can even use different designs for holidays or the changing seasons.  

If you’re not sure where to start, here are some examples of companies that are making corrugated boxes their own with incredible product packaging design:

Fuego Box

It seems like there’s a subscription box for just about anything these days.  

If you’re into adding some spice to your meals, then Fuego Box may be just what you’re looking for. Fuego Box specializes in craft and small-batch hot sauce. Their product is all about the heat and their corrugated packaging box beautifully reflects their brand.

Hot sauces come in glass bottles so, in addition to looking good, their boxes need to be protective. You can order one bottle at a time, but if you’re feeling adventurous you can try eleven different bottles in their “Tame-to-Insane” challenge box. 

The eleven hot sauce bottles come in a large roll-end front tuck box with dust flaps. The front flaps lock into the main body for strength and security, while the side flaps keep out the dust.   

Pop open the box and the inside is filled with deep orange and red colors that just imbue a sense of heat. You know you’re in for something spicy when you lift open the box. All eleven bottles are carefully nestled in cardboard cutouts, which gives a higher-end look and offers added cushioning. 

FunFitFun

The outside of a corrugated cardboard box offers a large area to cram some serious branding. Some companies merely print their name or logo in a single color on the side of the box, but others go much bigger and bolder.  

Lifestyle brand, FunFitFun has made full use of the entire corrugated box – inside and out.  

Four times a year the company sends out ecommerce packaging filled with beauty, fitness wellness, and home items. They’ll never be accused of being drab. They cover the whole outside of their boxes with colorful graphics, which they change up to reflect the season. 

As the brand’s name suggests, the boxes are all about projecting a fun, healthy vibe.   

Custom Branded Packaging Tapes

Even if it’s not in your budget to plaster your corrugated boxes with your company logo and fancy graphics, don’t assume you can’t make your boxes unique. 

You don’t have to go all out. You can add a little flair to your shipping boxes at just about any price point. 

You’ve got to seal that box somehow. Custom packaging tape can serve a dual purpose – securely sealing your packages for transport and getting your brand noticed.   

Using affordable, branding packaging tape around your boxes can go a long way. The classic example is, of course, Amazon. Their corrugated shipping boxes are simple, yet there’s no mistaking where that box is from once you see that recognizable black tape with the blue lettering.   

But you don’t have to be a behemoth of a company to customize your boxes. Even small companies can order packaging tape to add interest to an otherwise ho-hum box. So, get creative, and design a tape that pops.  

Patagonia

Corrugated boxes, for the most part, are rectangularly shaped for ease of storage and transport, but you don’t have to limit yourself. You can make them in just about any shape you want.  

Outdoor clothing company Patagonia prides itself on its commitment to the environment and wanted its packaging to reflect that. 

These hexagonal-shaped boxes are both eye-catching and functional. The corrugate was left in its natural state with minimal printing, but the shape gives these boxes a distinct look. Not only does the box design look cool. Corrugated cardboard can also easily be stacked on store shelves for a neat appearance. 

Get Started with Customizable Corrugated Boxes

Corrugated paper has come a long way since it was first introduced in 1856 and used as a liner for top hats.  

It’s hard to believe that something that’s been around since the 19th century is still so widely used today. There have been some improvements made to the material during the intervening years, but there’s a reason corrugated boxes have had such staying power. 

No matter your business, corrugated boxes offer many options. 

They can protect your goods, they’re easy to transport and store, they’re affordable, they can pump up your brand recognition, and they’re one of the better packaging options out there in terms of the environment. These boxes will likely be storing and moving items from one place to another well into the next century. 

The post The Ultimate Guide to Corrugated Boxes: Corrugated Packaging 101 appeared first on Refine Packaging.

Guess what you’re more than likely to find?  

Carton boxes.  

That’s right. The not-so-humble carton box is everywhere.  

Cartons house our milk, our cereals, our cosmetics, our kids’ toys, our electronic items – and so many of the other everyday necessities that constantly arrive in our homes.  

They’ve been around for eons and show no signs of disappearing.   

In fact, demand for cartons is on the upswing. According to Grand View Research, the folding carton packaging market size is predicted to be $171.35 billion by 2025. And not all of this growth is coming from the US. Thanks to a growing middle class, the Asia Pacific folding carton packaging market is expected to reach nearly $80 billion by 2025. 

More and more companies are realizing that the functionality, affordability, and aesthetics of carton boxes are hard to beat. 

Carton boxes protect the goods inside, are easy to open and use, are cost-effective, and they can attract a buyer’s attention. That’s quite an impressive resume for a simple folded piece of cardboard. 

Now, let’s dig deep into the world of carton boxes and see what they can do for you.

Carton Boxes Defined

Is a carton, a box? Most definitely. But a box isn’t necessarily a carton.  

We know, it’s confusing. 

Definitions of cartons vary, but rigid boxes or heavy-duty corrugated boxes generally aren’t considered cartons. And boxes made of materials, such as wood, aren’t usually referred to as cartons in the industry. 

To add to the confusion, cartons also go by various names. Sometimes carton boxes are called paperboard boxes, chipboard boxes, or folding carton boxes. 

But whatever you call them, you’re bound to find them in your pantry, your bathroom, and all over your house. 

There are many different definitions of cartons floating around, but one most can agree on is this: 

A Brief History of Carton Packaging Boxes

It’s hard to remember a time when grocery store or big box store shelves weren’t crowded with row upon row of colorful carton boxes – all vying for our attention.   

The first carton boxes looked a little different than what we have today. 

Charles Henry Foyle is credited with inventing carton boxes back in the 1840s. He used a piece of paper that was cut in such a way it could be folded to form a box.  

Initially, these boxes were held together by strings and tacks. As you can imagine, it was a very laborious process to make them, not to mention expensive. That’s why, in the old days, cartons were reserved for special luxury items, such as jewelry. 

This all changed when in 1879, Robert Gair accidentally discovered that his printing press could be used to mass-produce carton boxes. From then on, the carton box industry began to take off and has never looked back. 

With mass production, even simple everyday items could be packaged in cartons. This served a practical purpose – the carton packaging protected the items and gave them a longer shelf life. Cartons also provided a whole new way for companies to place their branding front and center. 

Benefits of Carton Boxes for Packaging

If you’re looking for a practical, beautiful, environmentally-friendly box to hold your goods, then carton boxes are the way to go. 

The Practical Side of Carton Packaging Boxes

First and foremost, the custom packaging needs to be functional. Let’s take a look at some of the practical benefits of carton boxes:

• They make efficient use of space. They’re lightweight and, because they fold flat, they can be easily stacked. This saves space in the warehouse.
• They offer ease of use. Folding designs make it easy to open and reclose packets.
• They’re suitable for automatic packaging. This makes it easy to fill and seal with automated machinery.
• They’re inexpensive. It’s not just the physical materials that are cost-effective.  Since cartons are lightweight and fold flat, they save on shipping costs.
• They offer tons of flexibility. Cartons can store all sorts of shapes, even liquids.
• They’re strong and durable, so cartons keep products safe.
• They can deter crime. Some companies are incorporating anti-theft and anti-counterfeit measures into their custom carton boxes. Grand View Research found that companies are increasingly using RFID (radio frequency identification) and embedded barcodes in cartons as a way to deter counterfeiters. 

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Folding Carton Boxes are Easily Customizable

Carton boxes are indeed functional, but don’t confuse that with being boring and simply utilitarian.  

You can infuse your carton packaging boxes with whatever personality you like and let your creativity shine. With an eye-catching carton design, you can set the retail boxes for your company apart from the competition.

A carton box is often your customer’s first impression of your brand. And we all know how important that is. Some research even suggests that people form first impressions in about 17 milliseconds. Now that’s fast.

Lucky for you, cartons are conducive to beautiful packaging design. Carton boxes were made to embrace the wow factor. Paperboard surfaces are printer friendly so it’s easy to incorporate eye-catching, colorful designs. You have many options with high-resolution graphics and can incorporate two-sided prints onto the cardboard carton boxes. 

You can let your creativity run wild – or you can hire a designer at just about any price point to get you started.  

Check out sites like Behance or 99designs that showcase designer’s portfolios. A quality designer can create a carton mockup that will help you find the right box size, shape, and colors to beautifully showcase your product. 

There’s also the more practical side to the easy printability of cartons. 

You can include product information right on the box. This is a major plus for food packaging, where detailed nutritional information can be printed right on the box.  

Ever been in the grocery aisle trying to decide between two competing kinds of cereal? 

We all know to flip to the side panel and boom. There’s all of the information we need to decide which one to grab. 

The versatility of carton box design is not just limited to graphic images. Cartons can easily be made into different shapes and sizes. You’re not limited to a predictable cube shape.   

You can also add other marketing options, such as cut-outs, that add interest and offer a sneak peek of the product.

The Environmental Benefit of Paperboard Cartons

Nowadays, a company that doesn’t take environmental concerns seriously, does so at their own peril. 

As consumers are becoming all-too-aware of the damage we’re doing to the environment, eco-friendly packaging is quickly becoming a must have component for brands.  

Consider that in 2015, global plastic waste volume reached nearly 6.3 billion metric tons. This figure is predicted to increase to 12 billion metric tons by 2050. 

No wonder single-use plastic containers have fallen out of favor, and are even banned in many instances. Even China, which is one of the world’s largest consumers of plastic, has said it will ban non-degradable bags in major cities by the end of 2020 and in all cities and towns by 2022.

As a result of the world’s waning appetite for plastic, companies are increasingly turning to the old standby – carton boxes. Let’s look at some of the environmental benefits that carton boxes offer: 

• Paperboard can be easily recycled. It’s non-toxic and can be reused. Carton boxes are also easy to break down for recycling, and consumers are more likely to make the effort to recycle. According to the EPA, around 44.2 million tons of paper and paperboard were recycled in 2017 for a recycling rate of 65.9 percent.
• Many carton manufacturers follow SFI and FSC certifications, which promote forest sustainability. Carton manufacturers are required to do their part, such as planting trees to replace the ones they’ve cut down.
• Many manufacturers of custom carton boxes are also making use of recycled paper pulp and non-wood pulp.
• Carton boxes are usually shipped flat, which cuts down on the amount of fuel needed to get these boxes to their destination. 

Drawbacks of Carton Boxes for Packaging

Of course, nothing’s perfect. Sometimes a carton box can’t fulfill all of your packaging needs and you’ll have to look at other options. 

Perhaps the biggest drawback of carton boxes is that they are not designed for shipping. Sometimes, carton packaging works well with your shipping and fulfillment needs, but note that cartons are not intended to be standalone or robust outer packaging.

Carton boxes are meant to be light-weight and easily stored. Unfortunately, to accomplish this, they have to sacrifice some of their strength. Carton boxes typically have a maximum thickness of 0.032 inches (.81mm), so they’re only meant to hold a few pounds at most.

Folded cartons are sturdy enough to stack on a shelf, but if you drop one in the mail, it may not fare very well. Cartons are generally meant for retail display applications – not to rattle around in the back of a delivery truck.

Most companies can’t rely solely on carton boxes for their goods. The carton packaging boxes may house the individual products, but to get from the manufacturer to store shelves, a supplier will need to opt for something a little stronger for transport. 

This is where corrugated boxes – which are much stronger – are a good option. Rigid boxes, which don’t fold or collapse, are also typically sturdier and can be used for certain applications when a carton box just won’t cut it. 

Common Folding Carton Box Styles Explained

After you’ve decided that you want to use carton boxes for your products, now comes the tricky part. It’s time to make some decisions. 

First, you need to determine which style will work best for your unique product. The options are almost limitless. There are so many different styles and sizes to consider, so your decision might feel daunting. You can truly go wild with your choices. And this is before you even think about the fun stuff like colors and fonts. 

Don’t worry. With a better understanding of what’s out there, you can find the right carton style for your product.  

Without further ado, let’s breakdown some of the most common styles of folding carton boxes:

Most Common Styles of Folding Carton Boxes

Tuck top boxes are one of the most popular folding carton box options. Here are some of the most common tuck top boxes you’ll find on the market:

• Reverse tuck end (RTE) boxes have the closing panels (sometimes called tuck flaps) on opposite sides. One closing panel is on the front of the box, the other on the back. These customizable carton boxes are easy to assemble, store flat, and are cost-effective. Reverse tuck end boxes typically use a slit-lock tab to close the ends. They’re great for light-weight items, but can’t handle anything too heavy.
• Straight tuck end (STE) boxes are similar to reverse tuck end boxes, except the tuck flaps are on the same side. This gives the box a cleaner look since you don’t see the raw edges. These customizable folded carton boxes are easy to assemble, store flat, and are great for light-weight items. They also typically use a slit-lock for secure closing. Straight tuck end boxes are usually a bit more expensive than the reverse tuck end boxes, since you get fewer boxes per paperboard sheet.
• Lock bottom boxes (sometimes called 1-2-3 bottom boxes) are meant for heavier items. They usually have a tuck top closure. As with the above-mentioned styles, these box cartons also store flat. Lock bottom boxes stack well and look better on the shelf since they have a flat bottom.  A lot of food items come in these types of box cartons. One drawback is they’re typically more expensive than some of the other carton box options.
• Crash bottom boxes (sometimes called auto-lock bottom boxes) are pre-glued on the bottom for extra strength. They have a bottom that goes into place automatically. Auto-lock bottom boxes also store flat and can be assembled and loaded quickly. Crash bottom boxes are usually more expensive, since the carton box manufacturer has to take the extra step to glue the bottom.  
• Top tuck boxes are what you might think of as a cake box, but they’re not just for pastries. These boxes offer a creative way to display other light-weight items, such as clothing or multiple small items. You can even add a little window to your top tuck boxes, so your customers can get a peek at what’s inside (see window patching below).
• Five-panel hanger tab boxes are like the reverse tuck end boxes, except they have a longer hanger panel that extends from the back panel. These offer a simple solution to display lightweight products in a retail setting. These custom boxes can be easily modified to include cut-outs, to give customers a better idea of your product. If you visit a pharmacy, you’ll see all kinds of products that utilize five-panel hanger tab boxes – everything from cosmetics to crayons (as shown in the following image). 

Your head might be spinning, but hang in there. Let’s switch gears and look at a handful of common features you may want to add to your folding carton box:

• Adding Inserts: An insert is a piece of paperboard that is folded, or sometimes glued, to fit in your box to secure loose items. This is a useful feature if you have fragile items or multiple items that you want to prevent from crashing around in the carton. Custom inserts can work with any folded carton type and are easily customizable to fit whatever random-shaped article you’d like to secure.
• Custom Cutouts: This is when you cut out part of the paperboard to show what’s inside. Custom cutouts can be made in any shape, so it can reflect your brand.
• Window Patching:  If you want to go one step further than a simple cutout, you could try window patching. Window patching is a thin plastic film that’s attached to the die-cut window (you’ll see this as part of your dieline as well). These windows are usually reserved for higher-end products and are often used to showcase food and beverage items, so customers can get a glimpse of the quality inside.
  
  Of course, one drawback with window patching is it uses plastic, which isn’t as environmentally friendly as paper products and may turn off some customers.  That’s why it’s so important that you know your customers and you make sure your retail packaging reflects your brand.
• Thumb Tabs: Thumb tabs are those little circular cutouts made in the main panel of the carton packaging to make the box easier to open.  

Practical Design Considerations for Carton Packaging Boxes

When you think of packaging design, your mind probably jumps to the fun stuff. 

What colors should I use? Where should I put my logo? But first, there are a few practical aspects of design you need to consider. Some of the most important elements to consider are your material selection, paperboard thickness and cost considerations. Let’s jump in.

Selecting Materials for Carton Boxes

Before speaking with you carton manufacturer, one of the first decisions you’ll need to make when designing your carton boxes, is what material do you want to use. 

Here are a few of the most common materials used for carton boxes:

• Solid-Bleached Sulphate (SBS):  SBS is made from bleached chemical pulp.  It’s a medium density board that’s coated on the top surface and sometimes on the reverse side as well. It’s white both inside and out, so it has excellent printing qualities. High-end graphics will look crisp on this material.SBS is also hygienic, doesn’t impart any smell or taste, and is approved for food contact. That’s why SBS is a popular choice for goods, such as chocolates, cigarettes, and perfumes. A bonus is it’s recyclable and relatively inexpensive. 

• Clay Coated News Back (CCNB): CCNB is a recycled board that’s made out of a blend of recycled newsprint, old corrugated containers, and mixed secondary paper. It’s less rigid than the SBS board. It has a glossy coated surface on one side and is grey/brown on the other. 
  
  CCNB is cheaper than SBS, but it has some disadvantages. Since it’s not a pure white color like the SBS board, it’s not as effective for printing and you’ll have to compromise a bit on the graphics quality. When it comes to colors, remember to discuss the differences between RGB and CMYK and Pantone colors with your manufacturer.CCNB also absorbs water, which means it needs to be kept dry. But if you’re looking to make low-cost folded cartons where recycled content is preferred, then CCNB may be the option for you. 

• Natural Kraft or Coated Unbleached Kraft (SUS or CUK): This is made from 100% recyclable materials. CUK is coated with a polyethylene resin, which is safe for food. Kraft paper is also strong, durable, and resistant to tearing, which makes it a good fit for items like heavy beverages. 

Paperboard Thickness for Folding Cartons

Next up, you need to consider the board thickness (the caliper). 

Paperboard comes in many different calipers, so you’ll have to make some decisions about what thickness is best for your product.  

It needs to be able to hold the weight of your product, but you also want to consider the assembly process as well. You don’t want to waste money and efficiency on an overly-thick board. 

To give you an idea of the thickness of a standard paperboard box, such as a cereal box or a mac and cheese box, those generally fall in the .016 or .018 caliper range. A counter display may use a more robust .024 point thick board.  

Cost Considerations for Carton Boxes

Of course, you don’t want to neglect the bottom line when designing your carton boxes.  

Most of the time, custom boxes cost less than you probably think. But that’s not always the case. You’ll want to weigh the cost of the materials and manufacturing efficiency. And sometimes, it pays to spend a little more. 

Consider whether you want to use offset printing or digital printing. Offset printing is often considered the go-to choice for bulk and wholesale custom packaging, but it’s not right for every company’s needs. 

Your choice might be slightly more expensive, but if it’s in your budget, it may be worth the splurge. It gives a higher-end look since you have more options with graphics and colors. 

Another thing to keep in mind is to take into account the scalability of any options you choose. The printing process is usually cheaper the more you order, so you may want to place a larger order all at once, rather than several smaller orders. 

Also, remember that old adage, time is money. You’ll want your cartons to be easy to fill with your product. An overly-intricate carton may look cool, but if it’s difficult to get your product in there, it’s probably not worth it.

Carton Box Design: Make Your Packaging Beautiful

Now for the fun stuff. Making your custom carton boxes beautiful and getting them noticed on a crowded shelf. 

Matte or Gloss Lamination: The Finishing Touch

One important aesthetic decision you need to make about your carton box is what kind of finish do you want. This is the lamination process, which is a protective layer that gives your box that finished look. You can choose between a matte or gloss lamination:

• A matte finish doesn’t reflect light, so it doesn’t have a sheen. It’s somewhat understated, but can give a sophisticated look. Scratches are less noticeable with a matte finish.
• With a gloss finish, light bounces off the surface, so it looks shiny. It’s more “in your face” than its more subdued counterpart. Gloss finishes are good at resisting dust and fingerprints. 

Either finish can look great and both have their pros and cons. It all depends on what message you want your custom carton boxes to convey. 

Learn more about finishing options to make your product packaging stand out. Read up about UV coating, soft touch coating and lamination, spot UV, embossing vs debossing and aqueous coating for a quick primer.

Branding: Printing Your Logo on Custom Carton Boxes

There are so many design elements that you can incorporate into a carton box, but the important thing is to not overdo it.  

It’s fine to use bold colors or some crazy fonts, but you don’t want to overload your customer’s senses. Sometimes it’s a fine balance between capturing a customer’s attention and turning them off with too much noise. 

Also, remember that your custom packaging is an extension of your brand and needs to reflect your company’s values.  It’s important to keep your branding consistent over all of your platforms – whether it’s your website or the packaging boxes that store your goods. 

Here are some common branding elements you might want to include on your carton packaging boxes:

• Your logo. You’ve no doubt put a lot of thought into that baby and it should have pride of place.
• Your colors. Even if your company doesn’t have a set color scheme, you should put some thought into what colors you want for the box design of your carton. Are you going for an earthy feel? Then go with muted, natural colors. Looking to convey some fun? Then go bold.
• Use materials that reflect your company’s values. If the environment is important to you – make sure your cartons reflect that. 
• Typography. Use a font that stays consistent with your brand identity. Don’t use a boring, staid font if you’re looking to project whimsy.
• Shapes. With cartons, you’re not limited to cubes. Look at Toblerone, the classic Swiss chocolatier. Chances are that you’d recognize the iconic chocolate bar just by the shape of the box.  

Read more about how to nail packaging design with our guides on ecommerce packaging, cosmetic packaging design and the unboxing experience to help get those creative juices flowing.

Carton Design Inspiration and Examples

Carton boxes come in all shapes, sizes, and colors. 

The choices can feel overwhelming. That’s why it’s sometimes useful to look at what other brands are doing. You don’t want to copy, just pull a little inspiration.  

Here are some examples of companies that are using custom carton boxes to effectively reflect their brands. 

Burlington Socks

Who said that socks have to be boring?

This fun carton design for Burlington socks adds a clever twist to a globally known product. 

Rather than using a usual cube shape for their sock boxes, they went with an unexpected sandwich box. The fun colors and bold font also give the carton packaging boxes a playful edge. 

Sojos

Sojos makes naturally nutritious raw pet food and gourmet treats. 

They incorporated many of the product packaging design elements we touched on earlier in their dog treat boxes. 

Sojos uses bold colors, has a window to offer a look at what’s inside, and even have a handle that can double as a hanger tab. 

It may only contain dog treats, but this box just exudes quality and fun. 

Crabtree and Evelyn

A carton box doesn’t need to be a crazy shape to command attention. 

Crabtree and Evelyn used an understated, yet eye-catching box design for their volcanic ash face mask. 

The carton matches the container inside. The sophisticated black background with white lettering and a simple gold image shows you don’t need to overdo the colors and graphics to make it stand out.  

The box radiates a sense of adventure, which is true to the company’s self-proclaimed vibe.

Beso Del Sol

Unlike a corrugated box, cartons aren’t limited to only containing solids. 

Beso Del Sol’s fun, sangria-filled, cartons quite literally look like a party in a box. 

When it comes to carton packaging, your imagination truly is the limit.

Lego

The classic blue Lego boxes may not be described as beautiful by many adults, but no matter what kind of carton you need, always remember your target audience.  

Lego plasters colorful, detailed pictures of their toys right on the box. They fill the front, back, and sides of the box with pictures of what’s included with the set. Kids want to see what’s inside.  

The larger carton boxes use close tabs so the toy can be stored back in the box when it’s broken down.  

Some Lego boxes have even become collectibles in their own right. 

Don’t believe us? Try searching “empty Lego box” on eBay.  

Get Started with Custom Carton Boxes

There’s a reason why carton boxes are so ubiquitous. 

And it’s understandable to have more questions than answers at this point. If you need help navigating through the carton boxes process, we’d be happy to speak with you. 

Refine Packaging has years of packaging expertise working with small businesses and Fortune 500 companies alike. Contact us today for a free quote on your custom packaging project. We’ll connect you with a live customer support representative who is able to answer any questions you might have.

Our team of designers are ready to help bring your artistic vision to life, who work hand in hand with our printing professionals that are ready to make your carton boxes truly shine.

Carton packaging boxes walk that delicate line of being both practical and potentially beautiful. 

Cartons are affordable, come in all shapes and sizes, can hold all kinds of goods (including liquids), are kind to the environment, and are a wonderful asset to your marketing arsenal. 

So, what are you waiting for?  

Start planning how carton boxes can help store and sell your products. There are so many carton options out there. You can come up with the right carton design to showcase your products at nearly any price point.  

Peruse store shelves for inspiration, choose what materials will work for your product, decide on the shape and size you need, figure out the logistics, and then pick out what finish and graphics you want. 

You can be as fancy as you want (or can afford). And don’t forget to have some fun.

The post The Ultimate Guide to Carton Boxes: Carton Packaging 101 appeared first on Refine Packaging.