Complete Guide to Custom
Product Packaging

Be it a new product or an attempt to renew your existing packaging. The success of your brand depends on the right of choice of the solution. The below guide will go step-by-step process and what your need to know about custom packaging, Are you waiting to take your brand to the next level? Ask Free Mockup or Look at Box Type.

What Makes Packaging More Important Than You Think

In the majority of situations, the first interaction customers get with your brand is your packaging. It is not merely a box to house the product, it's a strong marketing tool capable of guiding consumer purchases, building brand affection, and delighting with the unboxing process.

The Effect of a Good Packaging:

• Brand Recognition: Good packaging enables your customers to identify you on the congested shelves at a glance.
• Product Protection: The correct materials will make sure that your products are received perfectly as they are sent.
• Customer Experience: Elegant packaging develops positive feelings and presents a desire to go back and make an additional purchase.
• Shelf Appeal: Sellers with attractive designs make about 30 percent additional sales in retail markets.

Research indicates that 72% of the respondents believe that the design of a packaging determines their buying behavior. By investing in quality packaging you are actually investing in the future of your brand.

An Overview of Types of Packaging

Rigid Boxes:

The luxury brands exclusive option. Rigid boxes are extremely durable and provide a high-end unboxing sensation. Ideal to use in jewelry, electronic goods and cosmetics as well as luxury items which require to stand out.

Mailer Boxes:

Mailer boxes are specially made as eCommerce shipping containers. They are simple to assemble, offer strong protection during transit, and are very affordable for online retailers. These boxes also provide excellent branding opportunities, as they can be printed and fully customized.

Tuck Boxes:

Tuck boxes are cost-effective and flexible, making them ideal for smaller products. Their compact size allows them to occupy minimal space, which is perfect for retail environments where space is limited.

Display Boxes:

Custom Display boxes are designed to showcase your merchandise while remaining convenient for customers. They are perfect for encouraging impulse purchases and effectively displaying products.

Sleeve Boxes:

Sleeve boxes are designed for a sleek, premium presentation with a slide-to-open unboxing experience. Their minimalist structure adds a layer of sophistication, making them ideal for luxury items, promotional kits, or retail gifting. The sliding motion not only protects the product inside but also builds anticipation during unboxing — perfect for brands that want to leave a memorable impression. Their customizability and modern look also make them highly shareable on social media.

Mylar Bags & Flexible Packaging:

It protects against moisture, light, and oxygen — perfect for food or supplement packaging. Flexible packaging is ideal for foodstuffs, supplements, and products that require a prolonged shelf life.

Packaging Materials

The packaging materials have become an indispensable part of the entire packaging process that the key to the popularization of the packaging process could not have been imagined without the packaging materials. The picking of a proper material is key to guarding the product as well as projection of the brand. The following are the facts about most popular options:

Cardboard/Corrugated

Corrugated cardboard has a very good strength-to-weight ratio and it is very recyclable. It is best used to send boxes since it acts well as a package protector to most items.

• Single Wall Corrugated (3–5mm): Ideal option for shipping lightweight products. The single fluted layer offers enough protection for goods up to 2 pounds at a low cost.
• Double Wall Corrugated (6–7mm): A sweet spot for most shipping applications. Provides superior protection for products up to 10 pounds and offers good stacking ability for warehouse storage.
• Triple Wall Corrugated (15mm): Industrial-grade high protection. Can carry up to 50 pounds and offers outstanding crush resistance.

Kraft Paper

Kraft paper packaging is attractive to green consumers and gives a natural, organic appearance which is ideal in artisanal companies and brands that appeal to green consumers.

• Virgin Kraft Papers: Consist of fresh wood fibers, offering the highest strength and a clean look. Available in different weights ranging from 70 to 400 GSM.
• Recycled Kraft Paper: A green choice made from post-consumer waste. It has a slightly coarser feel but is great for brands that want to emphasize environmental friendliness.

Rigid Chipboard

The high level. It is a smooth tough paper offering an outstanding print quality and a high quality feel. It is the place to go when you need high fashion cosmetics, electronics and other luxury products.

• Solid Bleached Sulfate (SBS): The most desirable option for high-end packaging. Its smooth surface delivers top-notch print quality and can be customized with various coatings.
• Solid Unbleached Sulfate (SUS): Brown-colored with a natural appearance and superior strength. Commonly used in industrial packaging or applications requiring a rugged, sturdy look.
• Recycled Paperboard: Made from recycled materials, offering a cost-effective alternative. Unless finished, the gray core may show through.

Cardstock

The allround neutral center. Cardstock is fairly priced and provides decent quality prints with modest durability. Its uses are excellent in promoting mid-range products as well as packaging.

• Cover Stock (80–130 GSM): Ideal material for promotional use and light-duty packaging. Suitable for making folding cartons and inserts.
• Thick Paper (200–350 GSM): Offers good rigidity and is relatively affordable. Perfect for medium-duty packaging and specialty materials.

Metalized Substrates

Aluminum-coated papers and films are also great barriers with high-quality look. Ideal in food packages and luxury.

Plastic Films

• BOPP (Biaxially Oriented Polypropylene)
• PET (Polyethylene Terephthalate)
• PE (Polyethylene)

Foam Core Boards

Expanded, dimensional, light, and firm, ideal as point-of-purchase displays and as lightweight structural media.

Printing Methods and Finishes

Printing and finishing services right can turn a normal packaging into an excellent brand experience. Knowing these options will assist you make informed decisions that will respond to your brand objectives and budgetary restrictions.

• Digital Printing: The contemporary digital presses have high-quality prints with a fast turnaround rate. Ideal for short-run, variable data printing.
• CMYK Printing: Based on full-colour printing. Ideal for images, fades, and complicated graphics. Most applications are cost-effective.
• Pantone Color Matching: Duplicates the precise color every time. Essential for brands that require exact color consistency.
• Inkjet Printing: High-speed, large-format printing suitable for special substrates.
• Flexographic Printing: Ideal for high-end packaging, especially for large production runs and specialty substrates.
• Gravure Printing: Premium-quality printing suited for high-end applications and extremely large quantities.

High End Finishing Options

• Embossing & Debossing: Creates raised or sunken designs that can be felt by touch. Adds tactile interest and enhances value perception and brand recall.
• Foil Stamping: Applies colored or metallic foil to specific areas, often logos or text, for eye-catching effects and a premium appearance.
• Spot UV: Applies high-gloss coating to selected areas while keeping the rest matte. Adds contrast and makes specific design elements stand out.
• Matte vs Gloss Finishes: Matte offers a subtle, elegant feel, while gloss delivers a vibrant, energetic effect. Choose based on your brand’s personality and target audience.

By Industry Packaging Solutions

Packaging plays a vital role in different industries and you have to choose the best packaging solution as per your product needs. Overview of some industries are as follows.

Cosmetics:

The packaging required in beauty products is eye-catching yet protective. Cosmetic packaging must also be able to avoid contamination and also form a presentable packaging that signifies quality of the product. More value is added using high quality materials such as rigid chipboard and spot UV coating. Delicate items are ensured with custom inserts, and magnetic closures lend luxury to them.

Food & Beverage:

Packaging of food and beverages has to be up to standards regarding safety besides remaining fresh and attractive. barrier properties and FDA compliance is of vital importance. The mylar bags are highly moisture proofed and the food grade cardboard makes them safe. Various food products have the shelf life increased due to grease-resistant coatings and oxygen barriers.

CBD Products:

Packaging of CBD should have strict approaches and establish confidence with the consumers. Clearly there are child-resistant and clear labeling, this may become mandatory. Child-resistant closures on Mylar bags are preferred as these safety bags are required and prolong the freshness of the product.

Apparel:

Apparel packaging must be that which safeguards garments as well as generates enthusiasm towards the brand. An environmental focus related to sustainable packaging is given more and more attention in the fashion industry. Plain mailer boxes are very effective as a shipping container as well as Kraft paper attracts environmentally-friendly consumers. Personalized tissue paper and custom stickers can improve the opening process greatly.

• Retail/General: Retail product packaging must balance cost, protection, and shelf appeal. Versatility and brand consistency are key. Tuck boxes offer an affordable solution for retail displays, while display boxes are ideal for point-of-sale visibility. Flexible packaging also plays a big role, as it easily adapts to products of various sizes and shapes — making it a practical choice across retail categories.

Mylar Bags Barrier Protection at Its Finest

The usage of Mylar bags has grown in popularity in various industries because of its magnificent barrier functions and practicality. The packages used are flexible and provide a greater protection to moisture, oxygen, light, and odors.

1. Stand-Up Pouches: Ideal for retail display as they can stand tall on shelves. Perfect for snacks, supplements, and small consumer goods.
2. Flat Pouches: Suitable for products that don’t need to stand upright. A low-cost option for boxed or online-only items.
3. Gusseted Bags: Their expandable sides allow them to hold a larger volume while maintaining a neat and professional appearance.
4. Zip-Lock Mylar Bags: Resealable after opening, offering convenience to consumers and excellent product preservation.
5. Child-Resistant Mylar Bags: Feature secure seals that meet safety standards for cannabis, pharmaceuticals, and other regulated products.

Mylar Bag Applications

• Food Products: Exceptional moisture and oxygen barrier properties extend shelf life significantly.
• Supplements: Protects sensitive vitamins and minerals from degradation.
• Cannabis Products: Meets compliance requirements while preserving product quality.
• Electronics: Prevents static damage and moisture infiltration.
• Emergency Supplies: Long-term storage solution for survival kits and emergency food.

Sustainability in Packaging

New brands prefer to have environmental responsibility in their activities. It is not only the right thing to do to use sustainable packaging, it boosts the business.

1. Eco-Friendly Materials: We offer various environmentally friendly options such as recycled cardboard, FSC-certified stocks, and biodegradable films. These materials are less harmful to the environment and maintain high quality.
2. Sustainable Practices: We follow sustainability principles by using eco-friendly inks, minimizing production waste, and offering recyclable packaging options.
3. Certifications: We provide FSC (Forest Stewardship Council) certified packaging materials, ensuring they are sourced from responsibly managed forests.

Frequently Asked Questions

Common Packaging Mistakes to Avoid

• Choosing the Wrong Material: Focusing only on cost can lead to damaged products and unhappy customers. Consider the protection and branding your product needs.
• Ignoring Dimensions: Oversized packaging wastes material and money, while undersized packaging can damage products. Always confirm dimensions before production.
• Skipping Design Proofing: Never skip proofing. What looks good on a screen may not work in reality. Always review and approve a physical proof before production.
• Not Considering Shipping Durability: Packaging that looks great but arrives damaged is ineffective. Ensure it can withstand shipping and handling conditions.

Packaging Glossary

Die line: The form used to display how cuts, folds and other structural features will be positioned on the packaging.

• GSM (Grams per Square Meter): The unit of measurement for paper thickness and weight. Higher GSM typically indicates a thicker, more durable material.
• Spot UV: A finishing technique that applies a high-gloss coating to specific areas of a package, creating contrast with the uncoated sections.
• Lamination: A protective layer added to packaging, available in matte, gloss, or satin finishes. Enhances both durability and appearance.
• Bleed: The area beyond the cut line that ensures no white edges appear after trimming.
• Pantone: A standardized color matching system that ensures consistent color reproduction across different print runs.

How to Get Started with Us

It’s easier than you think to get started to get that ideal solution to your packaging needs. Here's our simple three-step process:

Step 1: Request Your Quote

Write to us with details of the product you want, the quantity needed, and any special design requirements. We will provide a quote within 24 hours.

Step 2: Have Your Mockup Approved

Our packaging design team will create a detailed mockup of your packaging. We’ll work closely with you until the design matches your vision.

Step 3: Production and Delivery

Once you approve the final design, we begin production. Your custom packaging will be delivered according to your requested timeline.

Are you prepared to go further with your brand through superior packaging?

Start With Us Now | Get A Quote | Check Our Gallery

At Product Boxes Shop, we believe in helping your brand to shine through its packaging that protects, promotes, and performs. Get in touch with us now and find out how the proper packaging can bring your business to the next level.

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