Introduction to Custom Cardboard Boxes
Cardboard boxes that are specifically designed and manufactured to meet a customer's unique specifications are known as custom cardboard boxes. Unlike standard, off-the-shelf cardboard boxes, custom boxes can be tailored to fit specific products, meet branding needs, and optimize functionality and efficiency in distribution and logistics.
Custom cardboard packaging is extremely popular because of its versatility and ability to protect products while promoting brands. The global custom packaging market size was valued at USD 272.7 billion in 2020 and is projected to expand at a compound annual growth rate (CAGR) of 4.4% from 2021 to 2028.
Cardboard is one of the most commonly used materials for custom boxes and packaging. It is lightweight, recyclable, printable, and can be cut and creased into just about any size or shape. Custom cardboard boxes provide excellent product protection as well as opportunities for shelf appeal with customized graphics and designs. They are an essential packaging component for thousands of products and industries.
Types of Custom Cardboard Boxes
Cardboard boxes are commonly used for packaging, shipping, and storing a wide variety of products. There are several main types of custom cardboard boxes to choose from:
Corrugated Boxes
Corrugated cardboard is a sturdy, thick paper-based material that consists of two flat outer layers with a fluted or corrugated medium sandwiched in between them. This corrugation allows the material to withstand pressure and impact.
Corrugated boxes are very versatile and come in single, double, and triple wall strengths. Single wall boxes are lightweight and economical, while double and triple wall boxes offer extra durability for heavy contents. These boxes can be customized with die-cuts, printing, and more.
Common corrugated box styles include regular slotted containers (RSCs), full overlap RSCs, half slotted containers (HSCs), full telescope designs, tray or rigid boxes, and die cut boxes. Corrugated boxes are ideal for shipping, storage, and display.
Folding Cartons
Folding cartons are constructed from paperboard, which is a thicker, more durable paper material. They fold down flat for convenient shipping and storage. When assembled, the seams are sealed with tape, staples, glue, or tuck locks.
These boxes can have custom shapes, coatings, printing, and more. They provide excellent print quality for branding and graphics. Folding cartons are commonly used for retail boxes, food packaging, and other consumer goods.
Set-Up Boxes
Set-up boxes are a type of folding carton assembled from die-cut and scored paperboard. They can rapidly pop-up or fold into shape when needed. Often used for gifts, retail products, and promotions.
The panels are prescored and the base is preassembled, allowing the box to quickly take shape. No taping or gluing necessary. Set-up boxes are impactful for displaying products while maintaining a small footprint for shipping and storage.
Customization Options
Cardboard boxes can be customized in a variety of ways to meet specific needs. Some key customization options include:
Size
Cardboard boxes come in a wide range of standard sizes, but custom sizes can also be produced. This allows you to get a box tailored exactly to the dimensions of your product. Whether you need a small jewelry box or a large shipping crate, custom sizes are available.
Shape
While most cardboard boxes are square or rectangular, custom shapes are also an option. Round, triangular, hexagonal – if you can draw it, it can likely be made into a custom cardboard box. This allows for unique branding and product presentation opportunities.
Print Design
Custom printing directly onto cardboard boxes is a great way to reinforce branding. Vibrant colors, high-quality images, logos, and text can all be printed onto custom boxes. From simple branding to full wrap-around graphics, print design options are versatile.
Die Cuts
Die cutting involves using custom steel rule dies to cut windows, holes, perforations, and other specialty features into cardboard boxes. This allows for visibility into the box, display features, ventilation, carrying handles, and more.
Special Coatings
Special coatings can provide additional functionality, protection, or aesthetic qualities to custom cardboard boxes. Glossy UV coatings provide a shiny finish, while matte coatings reduce glare. Wax coatings add water resistance. Soft touch coatings give a velvety feel.
With all of these customization options, cardboard packaging can be tailored to perfectly fit products while supporting branding and presentation goals. The versatility of cardboard makes it an ideal material for custom boxes and retail packaging.
Applications
Cardboard boxes are versatile and can be used for a variety of applications:
Product Packaging
One of the most common uses for custom cardboard boxes is product packaging. They provide a lightweight yet sturdy way to package, protect, and display products. Custom printed boxes allow brands to showcase their logo and branding while securing items during transport and storage. Everything from consumer goods to industrial parts can be safely packaged in corrugated boxes.
Retail Displays
Custom cardboard boxes are ideal for building retail displays. They can be used to create countertop displays, floor stands, and shelving units. Custom printing enables eye-catching graphics and messaging. The boxes are lightweight and easy to assemble yet strong enough to securely display products. Retail displays made of corrugated cardboard are an affordable and effective way to highlight products and promotions.
Shipping Containers
Due to their strength, custom cardboard boxes are one of the most ubiquitous shipping containers. They provide economical and secure transport of goods through the supply chain. Boxes can be specifically sized and reinforced to fit products and withstand the rigors of transit. Custom printing and labeling enables proper identification during shipping. Corrugated cardboard is recyclable, making it an environmentally responsible choice for packaging and shipping containers.
Benefits
Cardboard boxes offer several key benefits that make them a popular choice for packaging and shipping products:
Protection
Cardboard boxes provide excellent protection for the items inside. The corrugated cardboard material has cushioning properties that help absorb impacts and prevent damage during transit. Multiple layers of cardboard provide additional strength and durability. For fragile items, custom inserts and dividers can be used within the box for extra protection.
Presentation
The box serves as the “face” of your product upon delivery. A custom printed cardboard box allows you to reinforce your brand identity with colors, logos and messaging. The unboxing experience can be enhanced with custom shapes, printing and creative opening flaps. Quality packaging makes a strong first impression.
Cost-Effective
Cardboard is one of the most affordable packaging materials. It's widely available and costs less than plastic or wood crates. The cardboard itself has low material costs. Customizing options like printing are also very economical compared to other substrates. For many businesses, a custom cardboard box delivers maximum value for your packaging budget.
Recyclable
Cardboard boxes are highly recyclable, which is an important sustainability consideration. The paperboard material easily breaks down and can be re-pulped and turned into new cardboard boxes or other paper products. Recycling cardboard decreases waste and reduces demands on raw materials like trees. Many consumers now expect and appreciate recyclable packaging.
