Custom Boxes and Packaging Solutions Built Around Your Product

Custom boxes and packaging solutions are created differently than traditional boxes, as they are designed around the specific size, material requirements, and branding requirements of your product. From choosing the right material and creating the design to manufacturing the final product, every step is handled to create packaging that fits your product. This ranges from mailers to retail boxes, via display packaging and point-of-purchase solutions.

Custom Box USA is dedicated to designing custom packaging solutions, not to traditional sizes. We aim to make boxes that will help keep your contents safe, display your brand, and make the package opening experience great. This guide will help you to understand more about custom packaging options, box types, materials, and how the best packaging solution can make your business stand out.

Why Custom Packaging Matters More Than Most Brands Realize

A stock box can get your product from point A to point B. Not much else will happen. Custom packaging does the heavy lifting on all fronts, from protection to perception.

Protection Built for Your Product, Not a Generic Shape

Empty spaces are left by generic boxes. Damage occurs when there is a gap, and there is always a gap when there is anything that is moving. We customize each box to the product being put into it, meaning that there is no wasted space working against you.

Branding That Starts Before the Box Is Even Opened

Customers' first impression of your package is your logo on the outside. There's nothing that says a plain brown box. A branded box is an indication of your attention.

An Unboxing Experience Customers Actually Remember

Custom inserts, printed tissue, and a nice inside design make delivery a time to be shared. Marketing you don't have to buy twice.

Fewer Returns, Fewer Damage Claims

Damage in transit decreases when a box is the proper size and is made of the appropriate materials. That is actual cash saved on replacement and a discontented consumer.

Types of Custom Boxes We Build

We have created packaging styles to suit each product category and don't provide a single template. These are our favorite products to make.

Shipping and Mailer Boxes

Corrugated mailers that are designed for use in e-commerce, subscription boxes, and direct-to-consumer shipping. Corrugated boxes must not only look good on a shelf, but they also need to withstand a parcel network.

Retail and Display Boxes

Paperboard boxes are used for great shelf appeal, like for beauty products, supplements, chocolate, and other retail products where the box actually sells.

Regular Slotted Container (RSC) Boxes

The industry-standard shipping box style is designed to make shipping easy, efficient, and cost-effective – particularly for high-volume shipping operations.

Subscription Boxes

Repeatable packaging that is consistent; meant for kitting and recurring shipments, and designed to maintain the same brand experience with each box.

Gift and Promotional Boxes

Boxes used for corporate gifts, influencer mail and PR kits or promotional mail where presentation is as important as protection.

Swag Boxes

Designed for multiple use in your company's merchandise, event swag and employee kits – meant to be used and reused across a line of miscellaneous items, not a single product.

One-Piece Folder Boxes

Folds flat for storage and shipping, then opens up to become a full box without the need for a base and lid.

Folding Cartons

A style of carton that is lightweight and economical, ships flat and folds into a carton, typically used for retail products that do not require a turned edge or rigid carton due to the absence of a requirement for rigidity.

Turned-Edge Boxes and Luxury Rigid Boxes

Some products require packaging other than a simple folded box. We make turned edge boxes that wrap around a rigid edge for a polished appearance and Luxury Rigid Boxes, our superior line designed for brands who are looking for a high-end unboxing experience and a dense construction that doesn't need tape or glue to hold it in place.

Point-of-Purchase (POP) Displays

In the case of direct-to-shelf brands, we create your point-of-purchase displays, designed to grab the shopper's attention when they are making their decision.

Industry-Specific Packaging

In addition, we also manufacture boxes for certain categories of products, each designed to meet the specific needs of that product; namely, apparel boxes, candle packaging, bakery boxes and cake boxes, chocolate boxes, coffee and tea packaging, beverage and beer packaging, and jewelry boxes.

Materials We Work With

A box is made of something that dictates performance and appearance, so we do not restrict ourselves to any single stock option. The structural properties of the products are different. Here's what we offer.

Corrugated Cardboard

Our standard option for shipping strength, whether single, double, or triple-walled construction, based on the level of protection your product requires.

Kraft Paperboard

A natural and recyclable material suitable for brands who are more eco conscience looking to achieve a natural appearance, comes in brown kraft and grey bux board.

Cardstock

A paper that can be used for smaller, simpler custom boxes which don't require a full paperboard or corrugated build.

Plain Cardboard

Simple, affordable, and economical base material for simple, inexpensive custom boxes where price is more important than appearance of the finish.

Chipboard and Rigid Stock

More dense and expensive materials for boxes that are intended to be felt as substantial or rich in the hand, as in luxury or gift packaging.

SBS Paperboard

This is the standard package for retail use where the quality of printing and also the appearance of the package is of paramount importance – in this case it is available in C1S and C2S finishes.

Stock Weight Options

In addition, we provide 14pt, 16pt, 18pt, and 24pt SBS board, 100lb, 120lb, and 200lb printing stock, and the thickness of the material is the same as the material needs to survive.

Everything is environmentally friendly, decomposable, and easy to assemble without hassle for you.

Custom Packaging Specifications

When evaluating packaging partners, specs are important because it's not about what you are promised; it's about what you are getting. What's included in our custom packaging program is covered in the table below.

How We Compare to Off-the-Shelf Packaging

“There's generic packaging that's designed for no one, and that's the issue.” The difference is in our approach to building for your product, and it is reflected in three areas.

We don't work as a broker or reseller, so there are not as many handoffs or more opportunities for something to fall through the cracks between your design and your finished box. In addition, we have our own design and manufacturing capabilities, ensuring that changes are implemented quickly, rather than having to go through a third party.

ISTA Testing: The Standard Most Brands Don't Know to Ask About

That is determined by the International Safe Transit Association (ISTA). As more major retailers and fulfillment networks demand ISTA testing, packaging carries even more weight. Packaging is becoming more influential as major retailers and fulfillment networks demand that it be tested by ISTA before it is accepted into their supply chain.

ISTA 3A is used for direct-to-consumer shipping. It evaluates both drop tests from a variety of angles and transit vibration, plus stacking compression, so you can rest easy that your box can withstand the travel from warehouse to door.

Automated and Right-Sized Packaging Options

Additionally, we provide automated, right-sized packaging systems for high-volume fulfillment brands which enable brands to custom-cut box blanks as needed, rather than pre-made box stock sizes. This method reduces waste from void filling, and can accommodate items that are not easy to move through conventional packing lines.

This is for warehouses, distributors and fulfillment centers wanting to streamline their operations, rather than just a product brand ordering a set of retail boxes. This is something to discuss if your packaging requirements change as your order volume changes.

Sustainability in Custom Packaging

We are partnering with more brands every year who request eco-friendly packaging, and it's not something that we're charging extra for; it's just something that we have in our materials. You will find that Kraft and bux board are truly recyclable, biodegradable, and don't compromise on print quality.

Sustainable packaging is no longer a ‘values statement'. It's visible to customers, and it can be a part of brand trustworthiness before the box is opened.

Why Choose Custom Box USA

We have developed our ordering process to be as fast as possible, but still capture the details that really make a difference in creating a finished, professional box.

Full Customization: Selection of all box styles, materials, sizes, printing and finishing depends on the product and your brand.

Design Support: We have our own design team to assist you with artwork, sizing and layout before anything goes into production.

Fast Quoting and Priority Turnaround: If you are looking to get a quick quote, use our online quoting tool and if your timeline is shorter than our standard 10-12 day production window, ask us about Priority Turnaround.

Low Minimum Order Quantities: Order quantities as low as 100 boxes and small brands and new product lines are still within the reach of custom packaging.

Fast & Reliable Turnaround: Orders are picked up from the Design Approval to the finished product within 10 to 12 business days.

American Made Materials: We know exactly where to obtain materials and how to make them in-house, ensuring controlled quality and predictable turnaround.

Outside-the-Box: We also create complementary marketing materials, so your packaging and your promotional collateral are from the same source and have a consistent look.

FAQs

What is the manufacturing time for custom packaging?

Orders are processed in 10-12 days, after approval of the designs, except for priority turnaround, which can be done in a shorter time.

What are the materials you provide for personalized boxes?

Here we use a variety of corrugated cardboard, kraft paperboard, cardstock, plain cardboard, chipboard, rigid stock and SBS paperboard in different stock weights to suit your products.

Can I get eco-friendly packaging options?

Yes. Print quality is not compromised with our kraft and bux board materials, which are recyclable and biodegradable.

Do you ship boxes and retail display boxes?

Yes. We make RSC boxes, shipping mailers, retail-ready SBS boxes, subscription packaging, turned-edge boxes, swag boxes, and luxury rigid boxes in-house.

Are you developing packaging which complies with ISTA testing standards?

We manufacture shipping boxes & mailers for the Amazon ISTA 3A & 6-Amazon requirements that will help brands have a strong chance of gaining a bigger account at Amazon and other retail accounts that have requirements for certification.

Do you need packaging that is large-scale and automated?

Yes. We offer automated packaging solutions to fit the size and scale of fulfillment centers and high-volume shippers, including non-conveyable packaging.

Does my order include shipping?

Free Shipping for orders over $50.00. Give us a call for your project and get a no-cost, accurate quote.