Custom Boxes Built to Your Exact Spec
Printed mailers, folding cartons, kraft boxes and wrapped rigid boxes from 50 units. Free dieline, free US shipping, FSC paper options.
Custom Box Types We Manufacture
Every category below is produced to a written spec sheet: board caliper, flute, print method, coating and closure. Choose the structure that matches your product weight, shelf context and shipping route.
Custom Mailer Boxes
Roll-end tuck-front and tuck-top mailers built for courier handling and branded unboxing, printed inside and out.
Custom Kraft Boxes
Uncoated natural kraft with a visible fibre texture. Ideal for clean-label, artisan and refill-first product lines.
Corrugated Boxes
RSC and die-cut shippers in single or double wall for heavier SKUs, palletised freight and multi-unit cases.
Rigid Boxes
Greyboard wrapped in litho or specialty paper: telescope, hinged lid and magnetic closure builds with foam or card inserts.
Cardboard Boxes
Straight and reverse tuck-end folding cartons with auto-lock bottoms, hang holes and optional PET windows.
Display Boxes
Counter-top PDQ trays, shelf-ready cases and tear-away displays engineered to sit inside retail planograms.
Eco-Friendly Boxes
Mono-material, plastic-free structures using recycled fibre, water-based coatings and FSC-certified stock.
Gift Boxes
Presentation sets for seasonal drops, corporate gifting and bundle SKUs, with ribbon pulls and fitted trays.
Cosmetic Boxes
Beauty cartons sized around pump bottles, droppers and jars, with fitted card cradles and INCI panel layout.
Food Boxes
Food-contact board with grease-resistant or barrier options for coffee, snacks, meal kits and takeaway lines.
Bakery Boxes
Donut, cake and pastry boxes with locking lids, vent holes and clear PET windows for counter merchandising.
Retail Packaging
Complete retail programmes: primary carton, sleeve, insert, tissue and tape matched to one brand system.
From Spec Sheet to Delivered Pallet in Four Steps
No design experience required. A packaging specialist owns your job from the first measurement to the final tracking number, and nothing goes on press until you approve a digital proof.
Share your spec
Send internal dimensions (L × W × H), product weight, quantity and finish. Unsure of sizing? Give us the product and we measure clearance for you.
Free dieline & proof
Our team builds the dieline, sets bleed and safety, checks Pantone build-up and returns a 3D digital proof. Two revision rounds are included at no cost.
Print & quality check
Offset or digital print, die-cut, finish and glue. Every run is checked against the approved proof for colour, registration, caliper and fold integrity.
Ship, kit or store
Free US delivery with tracking. Need more? We kit, pick-pack and ship to individual recipients from our West Chicago 3PL floor.
Specification Detail Most Suppliers Leave Off the Quote
Packaging fails for measurable reasons: the wrong flute for a 6 lb SKU, a coating that blocks recycling, a carton 3 mm too tight for a pump. Here is how we specify to avoid each one.
Board selection matched to weight and route
Substrate is chosen from the product weight, the drop height it will realistically survive and the print coverage you want, not from a default house stock.
- Folding cartons: 14pt–24pt SBS for white brilliance, CCNB for value runs, kraft for uncoated texture.
- Mailers: E-flute (1.6 mm) for slim retail items, B-flute (3 mm) for glassware and heavier bundles.
- Shippers: single wall 32 ECT as standard, double wall BC-flute for freight and case packs over 30 lb.
- Rigid: 1.2 mm–2 mm greyboard wrapped in 128–157 gsm litho paper, with EVA foam or card cradles.
Print and finishing you can actually reproduce
Finishes are quoted with their trade-offs stated up front, so a launch batch and a reorder six months later still look like the same brand.
- Print: digital for 50–500 units, offset litho above 500 for tighter dot and lower unit cost.
- Colour: full CMYK plus Pantone spot matching; brand-critical colours are proofed before the run.
- Finish: matte, gloss or soft-touch lamination, spot UV, hot foil, blind emboss and deboss.
- Honest note: soft-touch film shows fingerprints on deep navy and black — we flag it and suggest matte varnish instead.
Sustainability claims scoped to your exact build
A box is only recyclable as manufactured. We define the claim you can legally print on the panel, based on the fibre, coating and any window film in the final structure.
- Fibre: FSC-certified virgin or recycled-content board available on request, documented on the order.
- Inks & coatings: soy-based inks and water-based aqueous coating keep kerbside recyclability intact.
- Design out waste: mono-material builds, plastic-free windows and right-sized dielines that cut DIM weight.
- Trade-off stated: lamination and metallic foil reduce recyclability — we say so before you commit.
Minimums, Materials and Lead Times at a Glance
Figures below reflect our current production standards for US-delivered orders. Use them to build a realistic packaging budget before you request a formal quote.
| Box Type | Typical Material | Standard MOQ | Production After Proof | Best For |
|---|---|---|---|---|
| Mailer boxes | E-flute or B-flute corrugated | 50 units | From 7 business days | E-commerce, subscription, PR kits |
| Folding cartons | 14–24pt SBS / CCNB | 50 units | From 7 business days | Retail shelf, cosmetics, supplements |
| Kraft boxes | 18–24pt natural kraft | 50 units | From 7 business days | Artisan, clean-label, refill lines |
| Corrugated shippers | Single / double wall C or BC flute | 100 units | From 8 business days | Heavy SKUs, case packs, freight |
| Rigid & magnetic boxes | 1.2–2 mm wrapped greyboard | 100 units | From 12 business days | Luxury, electronics, gifting |
| Display boxes | Litho-laminated E-flute | 100 units | From 10 business days | Counter PDQ, shelf-ready retail |
| Bakery & food boxes | Food-grade board, grease resistant | 100 units | From 8 business days | Bakery counters, takeaway, meal kits |
Lead times start the day you approve the digital proof and exclude transit. Rush production runs from 4–7 business days on qualified print-ready artwork. Volume pricing starts at $0.44 per unit depending on structure, board and print coverage; quantity breaks apply at 100, 500, 1,000 and 5,000 units. One order can carry up to 24 separate designs.
Packaging Programmes We Run Every Week
Examples drawn from real production: the detail that made each job work is stated, with no customer data attached.
Beauty & Skincare
Rigid sets with EVA foam cut per vial count (2 to 7 positions) plus matching outer cartons for retail shelf.
Cosmetic packaging →
PR & Influencer Kits
Press-kit mailers with a die-cut insert holding all eight items fixed in place through courier handling.
Mailer boxes →Bakery & Confectionery
Grease-resistant board, vented lids and PET windows sized so a 12-count tray stays flat in transport.
Bakery boxes →
Coffee & Beverage
Carton programmes for bags and cans, stand-up pouches with a degassing valve and printed cup sleeves.
Food packaging →
Luxury & Corporate Gifting
Collapsible magnetic boxes that ship flat and fold at your end, cutting inbound freight volume sharply.
Gift boxes →
Retail & Subscription
Monthly kit programmes: mailer, insert, tissue and tape produced together so each drop stays on-brand.
Retail packaging →Built for Small and Mid-Volume Custom Runs
Most custom printers price for 5,000-unit programmes. We are structured for the 50 to 5,000 range without pushing you into stock sizes or hidden setup charges.
01 Free design, not a design fee
Dieline construction, artwork preparation, bleed setup and two revision rounds are included on every order. There are no plate or setup fees on reorders of unchanged artwork.
02 One named contact
You work directly with a US-based specialist who holds your spec history, so a reorder does not restart the conversation from zero.
03 Price match on equal spec
Same structure, material, print method and quantity quoted lower elsewhere? Send the quote and we match it, in writing.
04 Proof-based accountability
Artwork, board and finish are checked against the approved proof before shipment. If the delivered order does not match that proof, we remake it.
05 Free US shipping included
Delivery inside the continental US is included on every order, with tracking issued at dispatch. International rates are quoted delivered.
06 Kitting and 3PL under one roof
Store packaging with us, then have us kit, pick, pack and ship to individual recipients from West Chicago, Illinois.
Fulfillment & 3PL →What Buyers Say After Delivery
Every review below is published under the reviewer's own name on Trustpilot or Google. Those platforms collect, host and moderate the content; we cannot edit or remove it.
“Teal Packaging went above and beyond to fulfill our order. They provided samples, verified everything in a timely manner and offered plenty of flexibility. We placed an order for 4,000 custom cardboard boxes on Jul 21, it was ready to ship Jul 26 and arrived Jul 31. Extremely happy with the quality.”
“I couldn't be happier. The quality of my custom boxes exceeded my expectations — they look and feel premium and truly elevated my brand. Turnaround was much faster than I expected, and the communication throughout was excellent.”
“Eva handled all of my design questions and gave creative recommendations that were used in the production of my packaging. Once the design was complete the shipment arrived within two weeks. Definitely a professional job.”
Individual results vary. Quantity, artwork complexity, finishing choices and destination all affect timing on any given order.
Get a Custom Packaging Quote in One Business Day
Send your box type, internal dimensions, quantity and finish. A specialist returns unit pricing, a production schedule and dieline guidance — no deposit and no commitment required.
- Reviewed and answered within one business day
- Free dieline, artwork setup and digital proof
- Price match on identical specification
- Structural samples available before bulk production
Ready to price your box?
- Have your internal dimensions and target quantity ready.
- Note your material, print coverage and finish preference.
- Tell us the date you need stock in hand.
Custom Packaging Questions, Answered Plainly
What is the minimum order quantity for custom printed boxes?
Most standard custom box orders start at 50 units. Specialty structures such as wrapped rigid boxes, magnetic closure boxes and certain laminated or regulated materials start at 100 units. Price breaks apply at 100, 500, 1,000 and 5,000 units, with volume pricing from $0.44 per unit.
How long does custom packaging production take?
Standard production runs from about 7 business days after digital proof approval, plus transit. Rush production runs from 4–7 business days on qualified print-ready artwork. Complex structures, specialty finishes and high-volume runs take longer; the exact schedule is confirmed in writing with your quote.
Do I need a designer to order custom boxes?
No. Our in-house team builds the dieline, sets bleed and safety margins and returns a digital proof at no charge. We accept AI, EPS, PDF, PSD and PNG artwork at 300 dpi or higher, and two rounds of revisions are included with every order.
Which materials and thicknesses can I specify?
Common specifications include 14pt–24pt SBS and CCNB folding carton board, 18pt–24pt natural kraft, E-flute and B-flute corrugated for mailers, single and double-wall C/BC-flute for shipping boxes, and 1.2 mm–2 mm greyboard wrapped in litho or specialty paper for rigid boxes. If you send your product weight and shipping route, we recommend the substrate rather than guessing.
Are your packaging materials recyclable or FSC certified?
FSC-certified paperboard, recycled-content corrugated, soy-based inks, water-based coatings and recyclable mono-material structures are all available by specification. Because claim scope depends on the material, coating and any window film, we state the exact certification and recyclability wording that applies to your job on the quote — including where a finish such as metallic foil reduces recyclability.
Can I get a physical sample before a bulk order?
Yes. Plain structural samples and material swatches are available for most products so you can verify fit, board caliper and finish before production. We strongly recommend a sample for first orders that include foil stamping, soft-touch lamination or spot UV, where the printed appearance differs noticeably from a screen proof.
Do you ship internationally and handle fulfillment?
Shipping is free within the continental United States, and we quote delivered rates to Canada, the UK, the EU, Australia and the UAE. From our West Chicago, Illinois facility we also provide kitting, pick-and-pack, storage and 3PL fulfillment — including shipping a single order out to hundreds of individual recipients. See fulfillment & 3PL for details.
How should I measure my box before requesting a quote?
Always quote internal dimensions in the order length × width × height, measured across the widest point of your product plus clearance: roughly 2–3 mm for a folding carton and 5–10 mm for a corrugated mailer that needs void fill. Our free packaging tools include a box size and dimensional weight calculator so you can check billable weight before locking a size.
Where You Can Find Us
Production support, quality checks and buyer communication across four time zones, coordinated from our US head office.
USA · Head Office
(224) 546-8325
1800 W Hawthorne Lane Ste 205
West Chicago, Illinois 60185
United Kingdom
+44 7342 050575
29 Stafford Road, Wallington
Surrey, England SM6 9AP
UAE
+971 50 105 8911
Office 1904, The Metropolis Tower
Opp Bay Square, Dubai, UAE
China
No. 3 Longxing Dongnan Yiheng Road
Baiyun District, Guangzhou
Guangdong, China