Custom boxes and cartons
Regular slotted cartons, mailer boxes, auto-bottom or manually assembled boxes, sized to the product and the pallet, in single-, double- or triple-wall corrugated board.
Expertise
Packaging and POS display subcontracting
Cardboard boxes, inserts, cartons, displays and POS units: describe your product and compare quotes from packaging manufacturers.
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Good packaging does three things at once: it protects the product in transit, it eases logistics (storage, palletising, handling) and it enhances the brand with the customer. For an industrial company, this means sometimes boxes and inserts that must arrive intact at the customer’s, sometimes a carton or gift box that contributes to the brand image, sometimes a countertop display or POS (point-of-sale) unit to promote a range.
Typical searches are “custom cardboard box”, “industrial packaging”, “custom foam insert”, “cardboard POS display” or “countertop display”. Quantities range from a few dozen units, digitally cut without tooling, to tens of thousands of pieces made with a dedicated cutting die. The process, material and printing depend on volume, product fragility and budget.
Here you will find the packaging families, materials, price levers, the files to prepare (cutting plan, proof) and the constraints to be aware of, such as the transport of dangerous goods or the export of wooden packaging, everything you need to request genuinely equivalent quotes.
Common services
Inserts and protection
Cut polyethylene or polyurethane foam, cardboard inserts, cell dividers and thermoformed trays: the part is held without play, which limits knocks and scratches.
Cartons and gift boxes
Product packaging in solid board or micro-flute, with printing, lamination, varnish, foil stamping or embossing depending on the brand positioning.
POS units and displays
Countertop and floor displays, totems and gondola ends in cardboard, wood, metal or plastic, delivered flat-packed or assembled, empty or filled.
Custom industrial packaging
Wooden crates, reinforced packaging for heavy parts, anti-corrosion protection, film wrapping: suited to machines and industrial parts.
Printing and personalisation
Flexographic printing on corrugated board, offset for flat board, digital printing for small runs and personalised versions.
Packing and logistics
Kitting, assembly, filling of displays, labelling, palletising and dispatch: the workshop can deliver a product ready to ship.
Materials worked
Micro-flute, single-wall and double-wall corrugated boardSolid board and folding board for cartonsCellular board and honeycomb boardPolyethylene and polyurethane foamKraft paper, void-fill paper and recycled fibresWood: crates, pallets and blockingPlastics: PET, foam PVC, corrugated polypropyleneFilms, bags and protective covers
Common applications
- Shipping fragile or high-value industrial parts
- Packaging for e-commerce products and postal parcels
- Cartons and gift boxes for cosmetic, food and technical products
- Countertop displays for in-store sales
- Cushioning of electronic components and machined parts
- Export packing of machines and heavy assemblies
- Presentation kits for trade shows and sales campaigns
- Reusable packaging for internal flows between factories
What affects the price
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1
Dimensions and quantity
The larger the packaging, the more the material costs. Conversely, the unit price falls sharply with quantity, because tooling and set-up are spread across the run.
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2
Material and thickness
The type of board, the number of flutes and the quality of the surface paper are chosen according to load and stacking; each extra level increases the price.
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3
Cutting die
A dedicated cutting die is an investment amortised over the run. For small quantities, digital cutting avoids the die but costs more per piece.
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4
Printing and finishes
Number of colours, printed area, varnish, lamination, foil stamping or embossing add steps and file preparation time.
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5
Assembly, packing and filling
A POS unit delivered assembled or filled with products costs more than one delivered flat. Handling time counts as much as the material.
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6
Logistics and storage
The transport volume of empty packaging, buffer stocks and staggered deliveries should be factored in from the request stage.
Tips for a successful request
Post a request- State the useful internal dimensions (length, width, height) and the product weight, rather than the external dimensions.
- Specify the mode of transport (parcel, pallet, export), the fragility and the stacking expected: this determines the board grade.
- For printing, provide a cutting plan as a vector PDF with cut and fold lines, together with high-resolution artwork.
- Ask for a white mock-up or a sample before the run, especially for a complex insert or POS unit.
- Mention regulatory constraints: dangerous goods, food contact, exports, mandatory markings.
- State the quantity, the ordering rhythm and your storage capacity so that production batches can be adjusted.
Sizing packaging: internal dimensions, cushioning and strength
It all starts with the product: its real dimensions, weight, fragility and sensitive points. Packaging is sized around its useful internal dimensions, to which the thickness of the cushioning is added. A box that is too large wastes material and transport volume; one that is too tight damages the product at the slightest knock. Think about the pallet too: a box size that fits without waste on an 800 × 1,200 mm pallet reduces transport cost.
Corrugated board is described by its flute. Micro-flute (E) is fine, around a millimetre and a half, and suits cartons and light parcels; B and C flutes, about 3 and 4 millimetres, are the most common for shipping boxes; double-wall BC reinforces heavy loads and stacking. The strength of a box is assessed through tests such as the edge crush test (ECT) for the board and the box compression test (BCT) for the complete box. For dangerous goods, only UN-approved packaging is permitted.
Cushioning immobilises the product: foam cut to shape, cellular board, thermoformed tray or paper. Technical foam prevents scratches on a sensitive product; cardboard cushioning is more environmentally friendly and is recycled with the box. For wooden export packaging, the international standard ISPM 15 requires treatment and marking of the wood. If your crate accompanies a large machine, anticipate the constraints with the assembly and handling workshop.
From cutting plan to proof: files and approval
For printed packaging, the manufacturer needs a cutting plan (dieline): a vector file showing the cut, fold and crease lines, to exact dimensions. The plan can come from the workshop based on your dimensions, or from your graphic designer. The artwork is then placed on this template, in high resolution, with bleed and colours defined in a print-ready mode. Standard designs are listed in the international FEFCO code (0201 denotes the regular slotted carton, 0427 the quick-assembly mailer box), which saves starting from scratch.
Before series printing, the workshop provides a proof, meaning a print to approve. Check dimensions, text, colours, legal notices, reading direction and recycling marks. The proof makes you responsible: once approved, a mistake is no longer the manufacturer’s responsibility. Sorting and recycling information marks, such as the Triman logo in France, may be mandatory depending on the products; ask your manufacturer or check the applicable regulations.
For small quantities, a white mock-up in digitally cut board validates dimensions, ease of assembly and the hold of the cushioning before the die is launched. It costs little compared with the price of an unsuitable cutting die. For unusual shapes, a prototype helps you decide.
POS units and displays: cardboard, wood, metal or plastic?
The material of a POS unit depends on its service life, the weight of the products on display and the image wanted. Corrugated board covers most temporary displays (promotional campaigns lasting a few weeks): light, economical, printable, recyclable. For use over several months or a heavy load, wood (MDF panels, plywood) offers rigidity and elegance, and is worked through joinery and digital cutting. Metal and plastic (foam PVC, PET, acrylic) suit permanent displays or a premium look.
Specify the weight and volume of the products to be displayed, the display height, the space available in store and the delivery method: flat (economical to transport but to be assembled on site), pre-assembled, or filled with products. A filled display needs careful packing to withstand palletising and handling. For bespoke metal structures, see sheet metal work.
In your Meaflow request, give the product dimensions, quantities and transport constraints: packaging manufacturers say whether they work with a cutting die or digital cutting, which immediately explains the price gap between two offers. Post your packaging request with your artwork.
Open requests: packaging & POS displays
Guides to go further
Writing a manufacturing specification: method and template
What a workshop needs to know to quote and make your part: a method in a few points, a ready-to-copy template and common mistakes to avoid.
How to Write a Subcontracting Quote That Stands Out
Read the brief, set out a credible price and lead time, include the right details and stand out from other workshops: a step-by-step method.
How to choose an industrial subcontractor: 10 criteria
Skills, capacity, quality, proximity, responsiveness, references, financial strength, communication, price and contract: 10 criteria and a comparison grid.
Related expertise
Wood & joinery
Fit-out, furniture, digital wood cutting
Textiles & garment making
Industrial sewing, tarpaulins, covers, marking
Prototyping
Functional prototypes, pre-series, models
Sheet metalwork & cutting
Laser, plasma and waterjet cutting, bending
Frequently asked questions
A question not answered here? Visit the help centre or write to us.
How much does custom cardboard packaging cost?
The price depends on the dimensions, the board, the quantity, the printing, the cutting die and the finishes. A small digitally cut run does not have the same unit cost as a large volume with a dedicated die. To compare, send the same internal dimensions, the same quantity and the same level of printing to several manufacturers.
What is the minimum quantity for a custom cardboard box?
It varies by manufacturer and process. Digital cutting allows runs of a few dozen to a few hundred pieces without tooling, whereas cutting with a dedicated die justifies larger batches. State your annual requirements: some manufacturers offer staggered deliveries against a volume commitment.
What file should I supply to have packaging printed?
A cutting plan as a vector PDF with cut and fold lines, together with high-resolution artwork, reference colours and mandatory notices. If you do not have a plan, give the product’s internal dimensions: the workshop can draw up the template. A proof will then need to be approved.
What is the lead time for manufacturing packaging?
Standard or digitally cut packaging can ship within a few days. Printed packaging with a cutting die generally takes several weeks, because the mock-up and proof often take longer than the production itself. Build these approvals into your schedule and state your deadline from the request stage.
Can I get a mock-up before launching the run?
Yes, it is even recommended for a complex insert or POS unit. The workshop makes a white mock-up in digitally cut board to validate the dimensions, assembly and product protection. Its cost is generally low compared with that of a cutting die or a run that has to be redone.
What packaging should I use to ship dangerous goods?
Dangerous goods require packaging approved under transport regulations (UN), with specific markings. Only specialist manufacturers or distributors can supply it. In your request, state the exact nature of the goods, the quantities per package and the mode of transport so that compliance can be checked.
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