The Ultimate Guide to Exclusive Custom Packaging Tips

The Ultimate Guide to Exclusive Custom Packaging Tips

In the modern world, several studies were conducted by different regulatory bodies to understand how custom packaging affects the buying behavior of customers. All studies demonstrate that customers remain attracted to eye-candy packaging that offers practical benefits. The introduction of e-commerce business in the mainstream markets has added competition to packaging. Companies are using appropriate and innovative packaging to sustain their existing customers and lure new ones to add to their customer base. The information also revealed that a significant chunk of the target audience shared images of the appropriately packaged products on social media platforms, which could become successful trends. There is much to ponder for innovative business companies, and it tells just how much influence they have to manipulate product perception.

However, not all businesses are ace at creating successful packaging in the first go. For many, it is a trial and error phase in which they learn from their mistakes. But, it does not have to be this way. We are drafting a simplified layout for newbies that is easy to understand and follow. It highlights the crucial questions and issues that one needs to focus on and ask from the relevant parties, including themselves, to order productive custom packaging boxes for shipping, display, branding, and storing. So, let’s get started;

1. Know What You Want from Your Custom Boxes

Whether looking for packaging options for large corporations or custom boxes for small business entities, one must remain mindful of the objectives one wishes to achieve via packaging. It brings us to the essential questions related to packaging;

  1. Evaluating available packaging options
  2. Pros and cons of cardboard-based packaging (for final selection)
  3. Selecting the best cardboard material based on product and retail requirements
  4. Estimating cardboard packaging costs (production, post-production, shipping, etc.)

The next phase requires self-evaluation of products for finding out crucial details using which the packaging companies will create mesmerizing packaging options. It includes studying the product to measure its weight, shape, and dimensions. At this stage, the product is also analyzed to find if it is damage-prone due to fragility and if it will require void fillers or other cushioning tools that the packaging companies offer. Details like the opening and closing box mechanism, international packaging-based symbols for better tackling orders during shipping, etc., are also considered depending on the product’s nature. It is imperative to be clear about the purpose of packaging at this point. Other points include;

  1. The clients must have a clear idea about their company’s budget for new packaging as it will help them set realistic goals and find affordable packaging boxes.
  2. The clients must have a clear idea about budget allocated packaging orders. Budgeting also helps finalize the packaging units required from the packaging company.
  3. It is essential to know about inventory status before ordering custom cardboard boxes. If planning to use new packaging options with events like a product launch, give enough time (at least six months) in between. For example, if the packaging is required for the fall season, summer is the right time to start this process.

Read About: Everything you need to know about custom boxes

2. Precision Guarantees Winning Custom Printed Boxes Wholesale Orders

One thing that can mess up all efforts and investments is an incorrect measurement of dimensions. It affects several areas and leads to, including;

  1. Additional Costs, e.g., void fillers
  2. Incorrect cost estimation
  3. Material wastage
  4. Misleading printing, production, post-production and shipping costs, etc.

There are certain things to remember when measuring for custom cardboard boxes;

  1. Always include the three dimensions: height, width, and length.
  2. To avoid miscalculations, measuring all dimensions in the same unit is essential.
  3. These three dimensions help packaging and printing companies calculate the volume of the ordered boxes using the basic formula; length x width x depth = volume.

Accurate measurement noted from the box’s interior will prevent the companies from getting larger packaging boxes, which might need void fillers to fill the space. It will help them reduce their carbon footprint and find the best fit for their products.

3. Identify the Different Product Packaging Types

When ordering retail custom boxes or packaging boxes, it is crucial to understand the categories they are divided into and their use. There are three categories of custom cardboard boxes, namely;

A. Folding Cartons

These are packaging and retail boxes that are crafted from cardboard paper that is available at economical rates. Durable or high-quality material is not used for this packaging type; instead, thin, flexible sheets compose various box layouts. This packaging type is mainly used for lightweight products or those that do not get damaged, and it is the most economical packaging type.

Read About: How to Differentiate Between Rigid Cartons and Folding Cartons

The most trending layouts in this packaging type include;

  1. Gable boxes
  2. Tuck boxes
  3. Pillow boxes

B. Corrugated Packaging

Depending on the material selected for custom corrugated boxes, they offer the sturdiest packaging and shipping options for heavy-duty items. The basic structure of packaging material includes two liner boards and the third layer of flute or wavy filler. The thickness of the flutes is increased according to the weight and the volume of the products. The purpose of flutes is to cushion impacts during shipping and transit and protect the product from all sides due to their thickness.

Apart from shipping boxes, the most trending corrugated retail box layouts include;

  1. Beverages carrier
  2. Subscription boxes
  3. Custom pizza box manufacturer in the USA

C. Rigid Boxes

Those who require luxurious options in packaging opt for custom rigid boxes, which come from the best cardboard material available that lasts for many years. This packaging type uses a thick greyboard covered with white paper for a uniform look. The exterior and the interior of these boxes are again lined with superior materials (e.g., printed high-grade paper, etc.) and fabrics for a look that converts them into retail masterpieces.

The most trending layouts in this packaging type include;

D. Other Options

Paper bags: Companies are trying to reduce their carbon footprint and opt for customized paper bags, which are cost-effective and a solution for a minimal packaging approach.

Poly mailers: The E-commerce entities providing smaller and durable products that are not damage-prone use this packaging tool as they are customizable at a low cost and offer a pocket-friendly solution.

Plastic packaging: This packaging comes in many forms but is considered highly damaging to the planet and its inhabitants. Plastic packaging is successfully being taken over by cardboard packaging for almost all sectors.

Glass packaging: It is costlier and more ostentatious than other options but offers the benefit of reusability!

4. Secure the Custom Cardboard Box Interior

As mentioned before, the internal inserts come in different types, including;

Foam-based inserts – They are used for fragile or high-end products like perfumes, medical instruments, stationery, etc.

Plastic-based inserts – They are often crafted as trays and used in custom shipping boxes for protection. They are also known in the shipping and packaging world as blisters. The product grooves and shapes are indented into these trays using heat, making them ideal for preventing product movement inside the boxes. The lightweight of these inserts does not affect the shipping weight.

Cardboard-based inserts – They are used as partitions, feces, and separators when multiple product packaging is required. Recycled cardboard is also available for this purpose.

Another option includes molded pulp-based inserts that are eco-friendly, biodegradable, sustainable, and ideal as a green packaging option.

5. Choose the Best Printing Option for Custom Printed Boxes Wholesale Orders

A. When to Use Offset Printing

In offset, printing toners are not used, which results in crisper, more precise, and richer image quality. The cost of plates is incurred once, which assists in the mass production of the order. All types of printed retail boxes and custom shipping boxes can be printed using this technology.

This printing type is preferred when;

  1. When large orders need quick completion time
  2. When clients demand reasonable rates against their high-end product printing needs
  3. When book printing is required
  4. Consistency in high-quality images
  5. Sharpness in the text is needed
  6. The quantity of the order is large as order cost will decrease with the unit increase
  7. When color matching and ink accuracy is a preference
  8. When visual content involves special inks like; metallic tones, etc.
  9. When the printed visual content requires distinction and customization using different add-ons

B. When to Use Digital Printing

Low volume orders that require instant completion are printed using this technology. It works similar to a home or office printer. This printing type works well for folding cartons and custom corrugated boxes but turns problematic for other material printing. Some reasons why digital printing is preferred include;

  1. It reduces the cost of printing plates as plates are not used in this process.
  2. It is an ideal choice for print-on-demand visual content
  3. It reduces manufacturing waste
  4. It helps produce multiple copies of the order
  5. This printing type helps minimize manufacturing costs
  6. It helps printing companies complete their orders faster

C. When to Use Flexography

This technology is also for large volume orders; however, it is ideal for rush orders as it is possible to print 750 meters in a minute. But colors printed using this technology are not vibrant. Moreover, it works best for printing one or two colors only. Some reasons to use flexography include;

  1. This process requires the least labor involvement after the first printing setup, as the entire process then becomes automated
  2. Because of automation, this printing technique remains the most cost-effective among others
  3. When printing order is large volume or requires quick printing
  4. This printing technique uses different ink types to create eye-candy details

Read About: The Ultimate Guide About Foil Stamping

6. Select the Most Effective Coatings and Finishes for Your Custom Boxes

a) Lamination

It involves using thin and transparent plastic sheets to cover the selected areas on boxes. Sometimes the entire box is covered using these sheets. It is available in two options matte and gloss. This coating prevents the boxes from dust and moisture, adding longevity to their life span. It gives a unique appeal to them and keeps the printed visual content from getting damaged.

b) Aqueous Coating

This coating is eco-friendly as it is water-based. It too is available in two options gloss and matte. One of the most beneficial attributes of this coating is its fast-drying time. It is important to remember that the shine or luster of AQ coating is milder compared to other options. This coating does not crack easily.

c) UV Coating

Another eco-friendly option used instead of lamination is ultraviolet-based coating. This coating adds a matte or a high gloss look to custom cardboard boxes. Under UV light exposure, this coating dries instantly, and the abrasion resistance of the UV coating is very high.

d) Varnish

This option is used when cost-effectiveness is a requirement. Although it can be coated on the custom printed packaging boxes in matte and gloss effects, it doesn’t last long.

e) Soft-Touch Coating

As the name suggests, this coating is velvet-like soft after drying and offers high gloss. High-end custom retail boxes often use this coating to give their products an edge over others in the market. This coating does not get yellow due to aging. A matte variation of this coating is also available for the clients.

f) Foil Stamping

Metallic or holographic effects are added t the selected visual content using this option. It helps highlight the branding elements and other vital details printed on custom cardboard boxes.

g) Spot UV

This technique is similar to UV coating; however, instead of the whole box, a selected area is chosen to apply this technique. The branding elements are highlighted using this option. Spot UV is also effective for using hidden logos and layers of design within the design.

h) Embossing and Debossing

This technique adds more depth and dimension to the printed retail boxes. Embossing raises the box panel in selected areas to create 3D content. On the other hand, debossing indents the box area chosen to highlight it. More add-ons can be added to this effect for eye-candy content.

i) Window Patching

This technique is used on cardboard retail boxes to highlight the product inside the packaging while protecting it. A custom-shaped window is cut out in the box panel and sealed using a PVC sheet. As a result, it allows the target audience to look at the products but not touch them. It is an excellent option for packaging food items, toys, devices, etc.

8. Compose Eye-Candy Themes

There are three options for clients when it comes to designing their printed packaging boxes, which include;

  1. Using in-house design department and resources
  2. Outsourcing the design to a printing company
  3. Outsourcing the design using online platforms like Upwork, etc.
  4. Selecting a packaging company that has its independent designing and printing set up

The fourth option is the most convenient, cost-effective, and viable one. But circumstances vary from client to client, so the selection is made accordingly.

9. Understand the Design Production and its Requirements

Once designs are completed, they get transferred to a structure template guided by die lines. These lines are created virtually using software like Adobe with accurate measurements and scaling. All designers must remain mindful of accuracy and artwork preparation rules to save time, money, and effort. This mathematical scaling and accuracy will ensure convenient editing of (vector format) images without damaging their quality or sizes. The only condition for using a rasterized file is when photo-based images are used, with a resolution of 300 DPI.

10. Request a Prototype

It is always helpful to request a sample box or 3D mock-up to identify any problem with the order before it goes into production. However, these samples are not always provided for free, and the client has to make a special request and follow the packaging company’s rules in this regard.

11. keep track of Production and Shipping

Upon finalizing all steps mentioned above, the waiting time starts. As mentioned in the earlier steps, all timelines are mapped according to the inventory status and packaging requirements. This approach will help companies receive their orders on time. All seasoned packaging companies allow their clients to keep track of their orders at all phases using online communication tools.

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