There are generally three types of boxes in the packaging industry: folding cartons or paperboard boxes, corrugated boards, and rigid boxes.
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.
What Are Rigid Boxes?Rigid boxes are formed from sturdy paperboard, provide incredible product safety, and are typically printed with elegant finishes to deliver a luxurious or high-end impression.
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 Features Rigid Boxes Folded Cartons Corrugated BoxesSetup
None if not foldable
Needed
Needed
Sturdiness
High
Low
High
Product safety
High
High with the aid of inserts
High
Cost
Generally high
Depends on printing and finish
Depends on printing and finish
Appeal
Generally high
Depends on printing and finish
Depends on printing and finish
Reusable
Yes
Usually not
Yes
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 BoxesWhat makes rigid gift boxes a great option for your business?
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.
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.
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.
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.
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.
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.
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.
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 PackagingRigid boxes may not be the best option if:
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.
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.
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 BoxesRigid box packaging styles are either two-piece or hinged:
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.
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.
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.
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.
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.
Brands can select from a variety of options when they want to go for fancy packaging.
Coating can come in different types:
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).
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.
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.
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.
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.
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.
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:
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.
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.
The packaging material itself also needs protection during shipment. This aspect should be considered and included during the design stage.
TestingAbout 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.
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.
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 AvoidUsing custom rigid boxes may turn to your disadvantage due to the following:
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.
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.
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.
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 PricesA 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:
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.
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.
The packaging industry also follows economies of scale, so small-run custom packaging projects will cost more than large ones.
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.
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 CostsHere are some workarounds to consider when you need to deliver rigid boxes on a budget:
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.
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.
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.
Although not as high-quality as offset printing, digital printing is more cost-effective, especially if you have a simple and minimalist design.
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.
The cost goes higher for every square inch where these treatments are used. Choose only the essential parts of your box for these finishes.
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.
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.
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 MakerAn ideal custom rigid box supplier should have the following characteristics:
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.
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.
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.
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.
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.
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.
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:
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.
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 BoxesRefine 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.
Glance in any pantry, peek into any fridge, look into the far reaches of a closet.
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.
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:
What are Carton Boxes?A carton is a folding box that’s typically made from paperboard. To form a carton, the paperboard goes through a cutting, folding, lamination, and printing process before it’s sent flat to whoever is going to fill the cartons with products.
A Brief History of Carton Packaging BoxesIt’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 PackagingIf you’re looking for a practical, beautiful, environmentally-friendly box to hold your goods, then carton boxes are the way to go.
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.
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.
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 manufacturersare 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.
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 ExplainedAfter 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:
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:
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.
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 boxesare 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.
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.
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.
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).
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:
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 insertscan work with any folded carton type and are easily customizable to fit whatever random-shaped article you’d like to secure.
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.
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 are those little circular cutouts made in the main panel of the carton packaging to make the box easier to open.
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.
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:
: 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.
: 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 cartonswhere recycled content is preferred, then CCNB may be the option for you.
: 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.
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.
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 BeautifulNow for the fun stuff. Making your custom carton boxes beautiful and getting them noticed on a crowded shelf.
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 finishdoesn’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.
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:
You’ve no doubt put a lot of thought into that baby and it should have pride of place.
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.
If the environment is important to you – make sure your cartons reflect that.
Use a font that stays consistent with your brand identity. Don’t use a boring, staid font if you’re looking to project whimsy.
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 ExamplesCarton 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.
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 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.
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.
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.
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 BoxesThere’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.