What’s both stylish and can be shipped directly in the mail? A mailer box!

These not-so-humble box mailers are not only durable (to keep your products safe), but they’re also highly customizable, so you can get your brand noticed and create memorable experiences for your customers.  

Mailer Boxes: Shipping Essentials for Ecommerce

In retail, mailer boxes can be used as gift boxes and for sending out promotional materials. They are easy to assemble and extremely effective for keeping ecommerce orders safe and secure. Mailer boxes are nothing new, but they’ve become more mainstream because of the thriving subscription box market. 

Subscription boxes, as we know them today, have only been around since 2004, but they are now a dominant feature of the ecommerce landscape. Consider this:

• Fuel by McKinsey estimates the total market size of the subscription ecommerce market is about $12 billion to $15 billion.
• A survey by Clutch found that 54% of online shoppers are subscription box service members.

Many of the products subscription services are shipping out arrive in mailer boxes. These boxes, usually custom mailers, are very versatile, so they can fit all kinds of items. Everything from razors and makeup, to video game accessories and dog treats, can be ordered through a subscription box service. All of these items can fit neatly and be attractively displayed in a mailer box.

Mailer boxes aren’t limited to subscription services. They’re commonly used to send out everything from books and business cards to jackets and computer keyboards. In other words, if you order things online, you’ve likely seen a mailer box. 

All of this translates to a tremendous amount of boxes arriving on people’s doorsteps. 

Let’s find out how you can get the most from mailer boxes and stand out from the competition. 

Building Your Brand with Mailer Boxes

Not so long ago, companies and their customers gave little thought to what kind of box their products were shipped in. They just wanted the item inside to arrive intact and to be what they expected. But times have changed. A company that ignores what their mailer boxes look like is missing out on a highly effective and lucrative marketing strategy. 

Sure, ordering online is convenient, but often, customers are looking for more. They want to be wowed by the complete experience, including the shipping mailer boxes their goods arrive in. 

Mailer boxes offer so much room for customization. Even if your company is just starting out, you can give your customers a special experience. Everyone from tiny Etsy stores to well-established brick-and-mortar stores use mailer boxes for shipping their products and increasing brand recognition.  

Mailer boxes offer a lot of flexibility. You can:

• Come up with a unique design that promotes your brand. 
• Make use of your logo, slogan, and brand colors.  

Remember to stay consistent with your branding across all of your marketing channels. Think about what colors you’re using on your website or what type of font you’ve used for your logo. You want people to see the mailer box and immediately identify it with your brand.   

Social Media and Unboxing Videos

Nowadays, social media is a key component of any marketing campaign, and unboxing videos are examples of initiatives that can skyrocket the value of your brand.

If you think people aren’t watching someone else open a box, think again. Try a cursory search on YouTube for unboxing videos, and you’ll be surprised at how many videos pop up. These videos are strangely addictive and popular.  

What is the first thing people see in an unboxing video? You guessed it – the box! You don’t want to skimp on your mailer box design and miss the opportunity to create that valuable first impression.

Two of the most influential YouTube unboxing channels are Ryan’s World with 28 million subscribers and Unbox Therapy with nearly 18 million subscribers. That’s a crazy amount of people tuning in to see someone else open a box. 

Sure, people tune in to these channels to see the actual products being unveiled, but they’re also enjoying the accompanying excitement of unwrapping the layers of packaging. 

If you want to get noticed by customers (or influencers), the overall presentation is important–and yes, that includes the box! A beautiful custom mailer can enhance your customers’ experience and even give your products a higher perceived value. 

What to Look for in a Mailer Box

Now that we’ve established the branding importance of mailer boxes, let’s talk about what makes up mailer boxes. As with all custom packaging, you want your boxes to be top quality. 

Here are some things you should consider when buying mailer boxes:

1. Paper Grades

Mailer boxes are primarily used to mail items and therefore durability is a must. That’s the reason why these boxes are usually made of corrugated material. It’s important to pick the right manufacturing paper for your purpose and products. 

Here are some common paper grade options for mailer boxes:

Kraft Corrugated Cardboard

These are the basic brown corrugated mailers we’re all familiar with. Kraft cardboard is an affordable option that gives you a rustic, natural look. Corrugated mailer boxes are made up of between 60-100% recycled material. 

Uncoated White Corrugated Cardboard

Some people prefer white corrugated mailer boxes. The look is cleaner, and graphics will stand out more with this choice. White corrugated packaging boxes also look high-end.

Clay-Coated Corrugated Cardboard

This corrugated packaging option gives you a smoother, brighter surface. It’s a little more expensive, so it’s a good pick for luxury brands.

Corrugated cardboard boxes also come in different thicknesses. Think about what you’re mailing. Is it lightweight? Fragile? Then decide on the flute grade (thickness) you need. Some common box mailer flute grades are E-flute 1/16 and B-flute 1/8.

Any kind of box can be dressed up or down, depending on your budget and the aesthetic you’re going for. A small budget is not an excuse to be boring. A simple brown box printed with your logo can create a lasting impression. 

Even if your budget is almost non-existent, you can customize your mailer boxes. Order a hand stamp with your logo or try a custom sticker. It’s all about making your boxes your own and reinforcing your brand. 

2. Closures

All of these boxes should be easy to assemble and need to be securely closed up somehow. Unlike regular shipping boxes that are often closed up with packaging tape, mailer boxes have some sort of tab-locking mechanism.  

Some mailer boxes come with additional protective dust flaps to keep dirt out. You can even choose a box with a tear strip for added security. If you’re mailing the box, you can further secure it with tape or hot melt glue, so it doesn’t pop open during shipping. 

3. Printing

You want your custom mailer box to create a good first impression as soon as it hits your customer’s doorstep. This means you want your text and graphics to look crisp and high-quality. Unintended blurry images are a no-go.

How good your graphics look comes down to the printing process you choose. There are several options out there, and there are a few factors to consider, namely your budget, any time constraints, the quality you’re looking for, and whether you are using your mailer boxes for shipping or retail packaging.  

You no doubt realize the important role colors play in evoking a certain mood or increasing brand recognition, so it’s vital to understand a little bit about how these colors are printed on boxes. 

There are two main color processes used when printing on mailer boxes: PMS and CMYK.

Pantone Matching System (PMS) 

PMS uses premixed ink formulas from Pantone, so you’re sure to get consistent colors across all types of mediums. With PMS, you get more vibrant colors. It is the best option if you’re using a lot of thin lines or metallic or fluorescent colors.  

If you’re using three colors or less, PMS is the cheaper option. But that doesn’t limit you to only three colors. You can “tint” colors to save money. For example,  if you’re using green, you can add a little white to come up with mint green.  

CMYK

CMYK is the other color option. It’s made up of four colors: (C) cyan, (M) magenta, (Y) yellow, and (K) black. This process creates the images out of tiny dots. It’s your best bet if you want to use full-color photos or need a lot of different colors. 

Now, on to the actual printing. There are two main options for printing on your custom mailer boxes: direct printing and pre-printing.  

Direct printing, sometimes called post-printing, is when you print directly on the box. This method is often used with corrugated boxes. 

• Flexography (or flexo) is a popular option. With flexo, you’re printing directly on the box. Flexo is affordable, has good printing speeds, can be quickly set up, and works well on both rough or smooth materials. Flexo uses PMS colors, so if you’re looking for full-quality photo images, you might not get the results you want.
• Digital printing is a printing method that’s gaining in popularity. It gives you higher quality than flexo. It’s fast but best for low volumes.
• Offset lithography (or litho) falls under the pre-printing category. It’s usually used for printing on custom labels, which are then glued to the box. This option is great for higher-quality photos or if you want to add some embossing or foil stamping. Litho labels can cover the whole box or just a small section. It’s up to you. 
• Foil stamping (or hot stamping) will give you an elegant, sophisticated look. Foil stamping is a printing technique that uses hot dyes to press a metallic print and foil onto the surface of the box. You can use a variety of colors, but a popular option keeps it simple – a black background with gold or silver foil. Foil stamping is usually found on the outside of the box. But why limit yourself? If you want something a little different, try it on the inside of the box.  

Keep in mind that these printing techniques aren’t mutually exclusive. Feel free to mix things up to grab your customers’ attention. 

If you want to get extra fancy, you can even combine direct printing with a litho label. Or if you want to splurge, go with two-sided printing. Whatever you choose, try to get the highest quality that’s within your budget. You don’t want to skimp on the appearance of your mailer boxes. You want them to look sharp and stand out. 

4. Finishes

Beautiful printing can be eye-catching and stand on its own. But if you want to elevate your product packaging design even more, consider adding a coating or other finishing touches. They can give your box a polished, high-end look.

Aqueous Finish

One popular and relatively affordable coating option is an AQ finish. This vegetable cellulose coating was introduced in the 1970s. The coating makes a box look shiny and smooth and protects it from smudges and scratches. You can opt for a glossy or matte finish – or even satin, which is somewhere in between.  

Another benefit of an AQ finish is it’s eco-friendly. Since it’s water-based, it’s nontoxic and can be easily recycled. 

UV Coating

This is a clear liquid coating that’s applied and then dried with ultraviolet light. This coating will give your box some added texture. You may want to opt for a spot UV varnish where it’s only applied to a specific area of the box. This is a great way to make a desired design element pop, such as your logo or slogan.  

To recap, here’s a table of the features and qualities to look for in mailer boxes:

Keep Your Custom Mailer Box Eco-Friendly

There’s no denying that e-commerce is booming. LimeLoop compiled data from the major shippers (USPS, FedEx, and UPS) and estimated that around 165 billion packages are shipped in the U.S. each year. But with all of these online sales comes huge amounts of waste heading to our already overflowing landfills.

This is concerning to customers and businesses alike. You can’t go a day without hearing distressing news stories about climate change or other impending environmental disasters. Sure, consumers love to buy the latest and greatest, but they’re also concerned about the environmental impact of their purchases. 

One study found that 74% of consumers were willing to pay more for sustainable packaging, and a quarter of these were willing to pay an increased cost of 10% or more. 

There’s no way to get rid of packaging completely, but customers appreciate companies that make an effort to be less wasteful. So give customers what they want. Box mailers not only look good, but they’re also one of the more eco-friendly options for packaging. 

Here are some reasons why:

• Most mailer boxes are made from post-consumer recycled materials.  
• Mailer boxes can be recycled again and again. They’re easy to break down, which encourages people to make an effort to put them in a recycling bin. According to the EPA, in 2018, approximately 32.1 million tons of corrugated boxes were recycled, which was a 96.5% recycling rate for corrugated cardboard boxes. That’s keeping a lot of packaging out of our landfills.
• Mailer boxes are easy to ship. They’re relatively lightweight and stack neatly in a truck, so it takes fewer trips to get them to their destination. Additionally, they’re usually shipped flat to retailers, which saves considerable space.
• Mailer boxes are usually made of corrugated cardboard materials, which biodegrade much faster than other shipping materials. Plastic, for example, can take upwards of 500 years to biodegrade. Embracing eco-friendliness isn’t lost on consumers. In a survey by consumer research firm Toluna, 66% of respondents said that paper or cardboard packaging is better for the environment.
• Retail and shipping mailer boxes are mostly made from materials sourced from sustainably managed forests. Look for companies that have FSC (Forest Stewardship Council) or SFI (Sustainable Forestry Initiative) certification for their corrugated mailers.
• Mailer boxes are sturdy enough to repurpose. You could use beautifully colored mailer boxes to store old postcards and other small mementos.

Eco-friendly doesn’t have to mean dull and monotonous. Sure, simply adorned kraft mailer boxes may convey the look you’re going for, but if you want to add more zing, there are many options. Today, you can find water-based, soy-based, and even algae-based inks that look beautiful and are good for the environment. So don’t let environmental concerns limit your color palette. 

Mailer Box Design: Be Sure You Get What You Want

With so many options for your custom mailer boxes, you want to get exactly what you want. No matter if you work with a designer or decide to go it alone, you want to make sure your mailer box design will fit your needs.

Are small mailing boxes the right size for your products? Make sure you can fit all of your goods comfortably. You don’t want a fit that’s too tight or to have your items swimming around in there. How about the graphics? Are the colors right?  Do your custom mailers with logo look good? Is everything spelled correctly?

When ordering custom mailer boxes, make sure to check the final proof. You can look at an online proof with a flat view, or perhaps a 3D mockup will help you visualize the final product. If you’re ordering a lot of mailer boxes and you have time, you may want to order a physical sample, so you know exactly what you’re getting.

Your shipping mailer boxes are the face of your business, so make sure you get everything just right the first time. You’d hate to order 1,000 boxes with your company name misspelled or the wrong URL emblazoned on the side. 

What Goes Inside Your Box

Mailer boxes are durable, but that doesn’t mean you can simply toss your items in and throw the box in the mail. There are certain things you may want to include inside.

Let’s start with protecting your product during shipping and fulfillment. Some items will fit perfectly snugly in the box and not need added padding, but for many items, you’ll need some sort of void fill to cushion your product so it’s not rattling around inside. 

Here are some common options for void fill:

• Packaging paper. This is an excellent way to fill space and protect your items. You can wrap individual items or ball the paper up to cushion your goods. Packaging paper looks decent and is recyclable.
• Crinkle paper. You’re probably familiar with the basic kraft crinkle paper. Color options are almost limitless. 
• Tissue paper. This is a simple, affordable option that can elevate the look of your packaging. It’s not the best for fragile items but works well for items like clothing.
• Cardboard inserts. Custom-designed inserts will protect moderately fragile items. Inserts are made to fit a particular item, so it’s best to use them on the products they were made for. 
• Foam cushions. If you’re shipping something fragile, this will help protect your items from scratches and breakage. You can cut the foam to shape to make it more useful. One big drawback is this type of cushion is not environmentally friendly. 
• Air pillows. These aren’t the most beautiful, but they’re lightweight, easy to store, and get the job done. 

In addition to protecting your products, throwing a few added goodies into your mailer box can make the experience more personal for your customers. That’s something most will appreciate. According to one study, consumers were 80% more likely to make a purchase when companies offer personalized experiences.  

So don’t waste the opportunity. It doesn’t take much to make your customer feel special.  Here are a few things you could include in your box mailers:

• Enclose a personalized thank you note. Or if you haven’t printed anything on the inside of a box, write “thank you” inside the top of the box. 
• If possible, use your customer’s name. In an Accenture survey, 56% of respondents said they were more likely to shop in-store or online at a retailer that recognized them by name.
• Toss in some coupons. People love discounts.
• Include small samples for other products. Your customer will feel pampered and special, and it’s a great way to introduce them to some of your other products.
• Add little toys, candies, or stickers. If you’re going for sophistication, this may not be the look you’re envisioning, but sometimes, a little frivolity is appreciated.
• Encourage your customers to share their experiences on their social media channels. Put your social media handles on the box with a hashtag you’d like to see trending. 

As with all marketing endeavors, presentation counts with mailer boxes. Of course, you need to work within your budget, but that shouldn’t stop you from adding a little something extra. Who knows? You might get lucky and a social influencer may share an unboxing video of your product.  

Perhaps more likely, customers will spread their impressions through word of mouth.  According to the American Marketing Association, almost 75% of consumers identify word of mouth as a key influencer in their purchasing decisions. And what better way to get them talking than getting them excited about your beautiful packaging? 

Corrugated Mailers in Action: A Little Inspiration

Having a lot of options is usually a good thing, but it can also feel overwhelming.  Sometimes, it helps to look at what others are doing. 

Here are some mailer box examples that will get your creative juices flowing and give you a good jumping-off point to come up with your own mailer box design:

1. Lily and Onyx

Lily and Onyx curates locally and internationally crafted goods that promote things like mindfulness and the “California” lifestyle. Their mailer boxes stay on brand. You can see the above packaging uses simple, tasteful, soothing colors, and typography that reflect the boho vibe the company is going for.  

As with their products, Lily and Onyx’s packaging has a natural look. You won’t find any wasteful packaging here.  

2. Love With Food

Love With Food, a snack delivery service, proves you don’t have to send out high-end goods to use stylish mailer boxes. Their service starts at just $7.99 a month, but they don’t skimp on their boxes. Their custom mailer boxes are bright red with white lettering, which reflects the branding on their website. The simple but bold color combination is sure to grab attention.  

3. Vegancuts

Sometimes, simplicity is the perfect reflection of your brand. Vegancuts offers snack, makeup, and beauty boxes. All of their offerings are 100% vegan and cruelty-free. They’re not about unnecessary excess, which is beautifully reflected in the simple line drawings and script on their printed mailer boxes. 

4. FabFitFun

Simplicity is not the name of the game for everyone. Popular lifestyle box subscription service FabFitFun is all about living life to the fullest. Their custom mailers are anything but subdued. Each season, they send out a new box with a new design. The boxes vary by the season, but they usually use several colors with images that cover the box inside and out. 

5. greenUP Box

What would you expect from a subscription box dedicated to reducing waste and plastics? Probably exactly what greenUP Box is sending out. Not only are their products all eco-friendly, but so is their packaging material.  

The leaf-covered design and earthy green color of the box are reminiscent of nature. The box and the crinkle paper inside can be easily recycled, so no waste here.

6. American Influencer Beauty Bundle

Sometimes, it’s all about the glam factor. American Influencer Beauty Bundle is a bi-monthly subscription service that gives customers exclusive access to influencer beauty products. Their shiny mailer boxes have a luxurious look that appeals to their customer base looking for the latest beauty trends. 

7. Smartass & Sass

As their name suggests, Smartass & Sass is all about “snark, sass, and sarcasm.” Their custom-printed mailer boxes might not appeal to everyone, but they reflect the company vibe and cater to their customer base. Spend a few seconds on their website and you just know this is a fun company with a certain brand of humor. 

Smartass & Sass uses boxes that look bold but are quite simple. It has kept the box for their secondary packaging to a single bright blue color with their name and a geometric pattern on top. They put their website address on one side and their catchphrase, “classy, sassy, and a bit smartassy,” emblazoned on another. Inside, they kept it plain to keep the emphasis on the quirky products you’ll find in the box.  

Every month has a different theme, so you never know exactly what you’ll get, which adds to the excitement. They even share unboxing videos on their website of past boxes, so you get an idea of what kind of experience you can expect when this box lands on your porch.

Put the Spotlight on Your Brand With Mailer Boxes

You’ve got a desirable product, so don’t leave your packaging decisions as an afterthought. Packaging should be a critical part of your marketing plan. It’s often the first thing your customer sees, so you want to get it right and make a great first impression. Think about what your company represents, and make sure your packaging reflects that.

A thoughtfully designed mailer box can up your game and boost your brand identity – and, in turn, increase your sales. Remember, customers are looking for the whole experience, so make your mailer box memorable and special. A quality mailer box can both ensure your goods get to your customers in one piece and – just as importantly – have them coming back for more.  

Refine 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.

The post The Ultimate Guide to Mailer Boxes appeared first on Refine Packaging.

Did you know that by deciding to ship or display your items in a cardboard box, you’re already ahead of the game? Yup, people are loving cardboard these days. 

A recent survey conducted by Ipsos found that:

• 71% of those surveyed said they were more likely to buy brands that package their products in paper or cardboard, rather than other materials like bubble wrap or plastic.
• 63% of those surveyed said that paper and cardboard packaging makes a product seem premium or high quality. 

Ok, so you’ve made the smart decision to package your goods in cardboard boxes, but is that enough to get your products noticed? Nope.  

You can’t just throw your goods in a nondescript box and call it a day.  No – in today’s world of unboxing videos and endless social media diatribes about the whole package opening experience, you’ve got to go above and beyond with ideas for your box design to stand out from the competition. 

Today’s consumers have so many options. They no longer have to rely on what’s available in their town – or even their country. They’re looking for a complete shopping experience – whether they’re checking out a store shelf, or browsing an ecommerce site. And they want the boxes their products come in to wow them. 

Think about what makes you buy a certain brand. Perhaps it’s word of mouth, or maybe loyalty, but more than likely packaging is also a major consideration.  

So, just how important is box design to your bottom line? Well consider this:

• A study by Ipsos found that 72% of Americans’ purchasing decisions are influenced by packaging design.
• 66% of those surveyed by WestRock said that they tried something new because the packaging caught their eye.

So, don’t leave box design as an afterthought.

It’s important to come up with a creative, yet practical, box design so you can fully leverage this powerful marketing tool.

Functionality Counts When Reviewing Box Design Ideas

Successful box design, like the custom boxes pictured above that we produced for Adidas, is much more than choosing your favorite colors to splash across the sides (albeit that is an important element).  

When coming up with your box design ideas and overall design plan, it’s essential to first understand the main functions of a box. 

Here are some fundamentals you don’t want to ignore with your box design when reviewing box design inspiration:

Your Box Must Protect What’s Inside

First off – and most importantly – your box needs to effectively protect what’s inside. 

If nothing else, you’ve got to make sure your custom box design keeps the items inside safe during shipping.

This means your box needs to be sturdy and tamper-proof. No one is going to appreciate a beautiful box if their wine glasses arrive in shards, or their poster arrives crumpled. You want your items to get to their destination intact.

Your Box Should be Efficient

The structural design of the box can play a large role in your bottom line, as well. When deciding on a design think about things like shelf and storage space. You don’t want to have an oddly shaped box if it’ll be difficult to store in your warehouse. 

Also, consider transportation costs when designing your box. The box size and weight of a box can unnecessarily jack up your shipping costs if you’re not careful.

Your Box Should Be Informative

It’s important that your box clearly labels what’s inside. When people pick up a box they want to know what’s in there, so, if there’s room, go on and include information about the contents, such as ingredients, expiration dates, or instructions on how to use the product. 

Packaging boxes are also a great place to add specific company information. A custom box has only so much marketing real estate, but you can point consumers to other marketing avenues, such as your website or social media channels, where you can offer more in-depth information about your company and products.

Your Box Should Reinforce Your Brand Identity

Yes, your box must offer protection, but that doesn’t mean you should ignore how it looks. Boxes are a great way to make a strong first impression and pump up your brand recognition.

The box design is not a place where you want to skimp. To fully harness this powerful marketing tool, you’ll want to have your logo stand out and make use of shapes and colors that represent your brand.  

Make a Design Plan for Your Box

Once you understand the important functions of a box, it’s time to come up with a design plan. To help you formulate your plan, it’s helpful to ask yourself a couple of questions:

What are you selling?

Boxes come in all different sizes, shapes, and thicknesses, so to get the right box (or boxes), you’ll need to have a clear idea of what products you’ll be putting in the box.

The size of your boxes and weight of your items will dictate a lot of your box options. Heavy items may need to be put in strong reinforced boxes, whereas you may get by packing lighter, smaller items into thinner carton boxes. 

You’ll also need to take into consideration whether or not the items are fragile. You obviously won’t want to pack a piece of stained glass in a flimsy, unpadded box.  Likewise, it wouldn’t make sense to invest in double-wall corrugated boxes if all you’re ever boxing up is socks.

For most companies, it might be difficult to get by with a single size box since many sell products of various sizes and shapes. But even if you sell only one type of product, you should think about whether multiples can be packed together in the same box.  

Who is your target audience?

No matter what products or services you’re selling you likely have an ideal customer in mind.  Who are you trying to appeal to? Think of the demographics of your target market.  Consider things like the ages of your customers, their income level, their geographic location, and what they consider important. 

Maybe you’re looking to sell upscale cosmetics to millennials, or maybe you’re trying to market paper straws to eco-conscious customers? Whatever your product, your packaging needs to represent your brand. 

Boxes are an essential component of your overall marketing strategy. You want to be consistent across all of your channels – including your website, social media accounts, and retail packaging. 

Your customized box design should reflect what your brand stands for. Sometimes a box is your customer’s first interaction with your product. So your boxes need to represent your products in the best possible light.    

Understand Some Basic Design Rules

Sure, you want your box design to be unique and stay true to your brand identity, but that doesn’t mean you can’t learn from other companies’ successes (and failures).

Here are a few tried and true design “rules” that will help get you started with your box design:

Color Counts 

When it comes to marketing your products, color plays a huge role. Studies have found that color increases brand recognition by 80% and that 85% of shoppers say that color is a primary reason for buying a particular product. 

Some colors are so iconic that if you look at them you know the company without seeing a logo or other brand identifier. Think of the classic blue Tiffany box that’s synonymous with luxury. Tiffany & Co. trademarked their “Tiffany Blue” in 1998.

Other companies have also successfully trademarked their colors, such as T-Mobile (magenta), UPS (deep brown), Wiffle Ball Bat (yellow), and 3M Post-Its (canary yellow).

Of course, not every company has a signature color, but successful brands know that certain colors evoke specific moods. You want your box colors to reflect the vibe you’re going for.  

In general, go for darker colors if you want to project a more staid, established look, lighter colors and pastels will give off a cleaner, more youthful look, or choose bright, bold colors to grab attention. 

Flonomics provides retail analytics to companies wanting to better understand how customers are interacting with their brand. They studied how different colors influence shoppers and their purchasing habits. They found that: 

• The color red stirred up feelings of excitement, passion, and energy.
• Blue gave off a trustworthy and reliable vibe.
• Green was all about nature, earthy feelings, and freshness.
• Orange was playful.
• And yellow was reminiscent of sunshine and evoked a warm mood.  

Put Some Thought Into Your Typography

How often have you seen a box with absolutely no words on it?  They’re out there, but pretty rare.  Most product box design involves some sort of typography. Typography is the arrangement of letters and words. It includes things like font sizes and styles. 

It can be fun to get creative with your font choices, but remember you want your words to both look good and be legible. Don’t overdo it with too many competing font styles.  That can just end up looking messy and clouding your message. 

Pay Attention to Quality

Put some thought into your materials. Flimsy, poor-quality paper packaging may be cheap, but is that the best look for your product? 

Definitely not, if you’re aiming to impress. Think about what you’re selling and have your boxes mirror the quality of your goods. Customers will expect their high-end purchases to come in a quality box. 

The same goes for graphics. A lot will depend on your budget, but try to use high-resolution graphics if you can afford it. An unintended, blurry image is not a good look.  

Don’t Have Too Much Going On

It helps to start with a focal point. If you have too many fonts, competing colors, and a hodgepodge of graphics, your message will get lost in the middle. You don’t want to overwhelm your audience with too many competing design elements. Instead, let your design elements complement each other and give them breathing space.

Of course, sometimes design rules are meant to be broken. Look at these box design tips through the eyes of your customer. The most important thing is to know your target audience and what look will appeal to them.

Don’t Be Afraid to Get Some Help

If all of this feels too overwhelming, seek another pair of eyes to look over your design, or hire a professional. Box templates (known as dielines) can often be found online, and you can find designers at almost any price point to help you come up with a captivating box design.  

If you’re on a super-tight budget, try Fiverr, or if you have a little more to spend try 99designs, Dribble, or Behance. 

If you need one-on-one box design support, the graphic designers at Refine Packaging are here to help. Contact us today for a free, no obligation quote on your custom box packaging needs and we’ll work with you to create a look and a package that brings together the very best of your brand personality, social appeal, and quality product design to create a look that is unmistakably your own. 

21 Box Design Ideas You Can Adapt for Your Own Packaging

Ok, you’ve got your plan and have a grasp of some basic design elements. Now, it’s time for the fun stuff. Let’s check out some box design eye candy. 

Here are twenty-one examples of companies who got their custom box design right by implementing various strategies:

Box Design Idea #1: Tell a Story

What better way to develop some rapport with your customers than to introduce yourself and tell your story. Stories are a great way to connect with your customers on a more personal level. Tell them who you are, where you came from, and what’s important to you.

In 2016 organic breakfast cereal company Kashi introduced “stories,” on the back of their cereal boxes. These little vignettes had full-color photographs and explained how the food was made and where it came from. They highlighted real people, such as farmers, millers, and others involved in the process of making the cereal. 

Of course, you can squeeze only so much copy on the back of a cereal box. That’s why Kashi also included a link to their website where the interested consumer could watch a more in-depth video on the subject. 

Box Design Idea #2: Use Patterns

Try using various patterns on your retail packaging boxes. Chevron, stripes, polka dots, and herringbone are popular options. Use them on their own or in conjunction with other images.  

Box Design Idea #3: Use All Available Space

A custom product box is more than a single side. Why not get more bang for your buck and cover the entire box with meaningful graphics, sayings, or information about your brand.

There’s a reason, lifestyle brand FabFitFun’s subscription box designs are splashed all over Instagram and are featured in so many unboxing videos on YouTube.  

They change up their mailer boxes depending on the season, but they usually use bright graphics and take full advantage of the entire box – inside and out.

Box Design Idea #4: Keep it Simple

Dutch company Slopes & Town sells accessories, such as multi-purpose belts and socks made from bamboo fibers and recycled plastic. 

The company’s mantra is an emphasis on sustainability and keeping waste to a minimum. This includes its eco-friendly packaging, which is often made from kraft paper. There’s no excess with their custom boxes.

Box Design Idea #5: Don’t Forget the Inner Sections

The outside of a box may give the first impression, but that doesn’t mean you should ignore what’s inside. 

Tait Design Company’s Turbo Flyer comes in a box that doubles as a cardboard carrying case. The multiple pieces of the balsa model airplane kit fit neatly inside. So, whether you want to store it in your closet, or take it to the park, you know your airplane will be secure.

Box Design Idea #6: Use an Interesting Shape

Boxes don’t have to be cuboids. They’re usually rectangular for ease of storage and transport, but there’s no hard and fast rule saying you can’t have a triangular, hexagonal, or whatever-shaped box. Below is a prism-shaped box concept for a soap company. 

Box Design Idea #7: Remember Your Product

Always keep your product in mind. Your box and packaging should reflect what’s inside. Take, for example, the Australian company, Young Willow, which specializes in stylish, high-end baby gifts, including clothing, bibs, books, and little toys. 

One glance at their website and you can see the sophisticated look they’re going for. There are no garish primary colors to be had with this brand – everything looks soft and subtle. Their boxes further reflect their brand image. 

Baby showers are big business and what better way to elevate the gift experience for that mother-to-be than to present your gift in a gorgeous box. Young Willow’s gift boxes are so pretty, they sell them as a separate item on their site.

The custom packaging boxes come in soft muted colors, such as lavender, green, and pink pastels, with the brands’ name embossed on the top. Pop open the box and the muted color scheme continues inside. This is a box that will not likely be casually tossed in the recycling bin.  

Box Design Idea #8: Add Some Fun

Depending on what you’re selling a little frivolity can go a long way. A nice warm plate of cookies can bring out the inner child in anyone. Thelma’s decided to have some fun with their cookie boxes. 

Instead of packing their cookies into one of those ubiquitous, pink pastry boxes, they went for something much more memorable, a distinct oven box.  I can almost smell those cookies.  

Box Design Idea #9: Go Bold

When you think of mid-century modern design, iconic industrial designers, Ray and Charles Eames likely spring to mind.  They received numerous design awards and their furniture has been exhibited in museums throughout the world. 

So, it’s no surprise that a lot of thought went into the customized boxes housing a product as simple as children’s building blocks. 

Eames House Blocks are packaged in a carefully designed box that reflects the Eames’ sophisticated, but non-fussy brand. The box is a simple shape and the graphics aren’t very complicated, but it gets its boldness from the sharp geometric shapes infused with strong red and black colors. 

Box Design Idea #10: Make it Gift-Worthy

Sometimes a beautifully designed custom box is as much a part of the gift as what’s inside. In many cultures, tea drinking is a ritual. Teabox brings this experience into people’s homes with an assortment of beautifully appointed gift boxes.

Slide open the beautifully illustrated box and you’ll find two gourmet blends of Indian tea in glass vials nestled inside. The gift-like box design elevates the experience for the recipient.

Box Design Idea #11: Use a Single Bright Color

You don’t have to use a rainbow of colors to capture attention with your box. A single color can make a bold statement.

Kong Box sends out monthly boxes full of dog toys and treats. The goodies are shipped out in bright red boxes. You’ll also find this same vivid color throughout their website. 

Box Design Idea #12: Add a Packaging Sleeve

Often a company will use a packaging sleeve in place of a box since it can be a more affordable option. You’ll often see these sleeves used on a bar of soap or a pair of socks. But some companies incorporate this element into their overall custom box design. 

Mother E Essential Oils uses a standard box design to store their essential oils. Where they mix it up is with their packaging sleeves. They use different sleeves depicting various nature scenes depending on what essential oils are in that particular box.  If they ever want a new look, a sleeve is much easier to change up than a whole box redesign.

Box Design Idea #13: Experiment with Fonts 

Something as simple as using an interesting font can elevate the look of your custom box design. You can go modern or vintage, quirky or traditional, winsome or staid – just be sure to make it memorable and unique. The right font can help boost your brand recognition. 

Skoff Pies used several different fonts that compliment each other to come up with a retro vibe for their comfort food pies. 

Not sure where to get started? The internet is a treasure trove of fonts. Check out sites like Google fonts or Behance to find free ones, or, for a wider variety, splurge a little and buy one from Creative Market or MyFonts.

Box Design Idea #14: Use Product Photography

Photographs are a great way to showcase your product. If you decide to go this route make sure to use high-quality product photography.  

Anovo used a picture of their product, as well as small pictures of fresh-looking food, including steak, salmon, and asparagus on their nano precision cooker boxes. But the photos aren’t overwhelming. Anovo went with plenty of white space to make the colorful photos pop and appeal to both your eyes and your taste buds. 

Box Design Idea #15: Try Some Humor

Humor can be a little tricky since we all find different things funny.  But when it works, it works. Just remember to keep your target customer in mind. You don’t want to offend anyone.

Box Design Idea #16: Give ‘em a Sneak Peek

Cutout windows offer your customers a glimpse of what’s inside, and sometimes the option to touch your product. Cutout windows, which are accomplished through the window patching process, are often used for food items so you can see what you’re buying. Who wants to splurge on expensive cookies, if you discover they’re a crumbled mess when you open the box. 

Cutouts are also a good option if you have a colorful or textured product. Zandra Beauty sells a variety of artisan soap bars that come in different scents and colors.  Each variety of soap is a different color and comes in different cosmetic packaging.

The little cutout gives you a glimpse of the colorful bar of soap inside. You could make quite an attractive display on a store shelf with all of the different colors peeking out.

Box Design Idea #17: Make it Multi-Purpose

Sometimes the box is a work of art. Check out the latest beautifully illustrated box from CauseBox. CauseBox is all about curating socially conscious items for their subscription boxes. You’d feel bad tossing this box in the recycling. It would make stylish storage for old letters or other small mementos. 

Box Design Idea #18: Use a Limited Color Palette

You don’t have to use every color in the rainbow to make your boxes interesting.  For a softer and more sophisticated look try different shades of the same color. 

One popular design trend for custom boxes that’s been incorporated in everything from painted walls to cakes and hair dye is ombre. Ombre is when you blend one color hue to another, usually going from light to dark. Why not try it in your product box design for a current look?

Glossybox is a subscription beauty box service. They frequently redesign their ecommerce packaging boxes depending on the season. Their current holiday box beautifully blends different shades of pink for a cohesive look. 

Box Design Idea #19: Use a Custom Stamp

Sure, it would be great to have custom beautifully designed boxes with your logo embossed on the sides or printed in an array of colors. But that’s not feasible for every company’s budget.  But don’t fret, there are affordable design elements just about any business can incorporate in their cardboard box design.

If you’re strapped for cash, or you’re just looking for a simple aesthetic – then consider a custom stamp.

Etsy shop, HeirloomHomeStudio, designs and produces porcelain tableware that’s inspired by the farm-to-table movement. Their brand stresses simplicity and their products have a vintage look. This vibe is beautifully reflected in their understated stamped boxes. 

Box Design Idea #20: Seal Up Your Boxes with Something Pretty (or Practical)

Another affordable packaging box design option is colorful, or branded packaging tape. Packaging tape can be used for brand promotion, handling advice, reducing theft, or to advertise other products. Since you can order packaging tape in small quantities, any company can take advantage of this affordable, low commitment option. 

Box Design Idea #21: Use Custom Labels or Stickers

You don’t have to print your graphics on the actual box to get a professional, attractive look. Maybe you don’t feel like committing to a single product box design.  A well-designed sticker or label will look good and allow you to easily change the look of your boxes depending on your mood.

Nosejoy is a fragrance subscription box service. Each month, they send out four to five scent-filled items, such as candles, soaps, or lotions from upscale boutique brands. 

They completely change the look of the box each month by using a different sticker on the front.  One month it might be deep blues with a mermaid picture, the next month might be all about bright yellows with pictures of lemons.  

Get Designing and Bring Your Box Design Idea to Life

Your custom packaging should never be an afterthought. Boxes and other packaging materials are far too important a marketing tool to ignore. Thoughtful box design strategies like the ones mentioned above can help you attract new customers and retain your current ones. 

Keep in mind that various box design elements aren’t mutually exclusive. You can incorporate several into your design – just don’t let it look too cluttered. You may need to experiment a little to find the right fit. You want your message to shine through and be consistent across all of your marketing materials.

Everyone from small Etsy stores to giants like Amazon put a lot of thought into their shipping box designs. Quality design doesn’t have to cost a fortune. It can be as simple as a sticker, or as fancy as a multi-colored embossed high-quality box. The important thing is that your product box design reflects what’s important to your customers and your company.

The post Pump Up Your Packaging Game With These 21 Box Design Ideas appeared first on Refine Packaging.

You might not think much about the product packages that arrive on your doorstep. 

But did you know that product packaging has different levels? 

Known as primary, secondary and tertiary packaging, each package has its place and its purpose. 

In this article, we’re going to reveal the differences between each type of packaging, when each one is used, why they matter and how to find a professional packaging company to help ensure your product packaging is designed right every step of the way. Let’s take a closer look. 

Primary Packaging 

Primary packaging is the packaging that comes in direct contact with the product itself.

A cereal box wouldn’t be considered primary packaging, but the bag inside the box would, since it’s the part that actually holds the contents of the box. If all cereals were contained in the box alone (without the bag), they’d be much more susceptible to going stale or being affected by moisture or light, which could degrade their taste, texture and consistency. 

The main job of primary packaging is to protect and preserve the product inside. In this example, bags are rather clunky and liable to slip out of your hands. Plus, they don’t exactly fit neatly in a cupboard. It’s harder to print information about the product on them, and thus we have the bag inside the box — to keep the product fresh and outside of light, moisture and other elements that could affect it. 

Primary packaging is often referred to as retail packaging, although this term is sometimes used to describe secondary packaging as well. Using our cereal example above, primary packaging doesn’t just reference the bag that the cereal comes in, but the box that the bag is stored in, as well. As you’ll know if you’ve ever been down the cereal aisle in the grocery store, the brightly-colored boxes with deeply-textured images of cereal are designed to attract your eye and your attention. 

In terms of what’s considered primary packaging, you can think of it as the answer to a simple question — is this the packaging that the product is normally bought in? If so, then that would be considered its primary packaging. As another example, carbonated drinks are kept in a can — the can would be considered the primary packaging because it’s how the product is delivered to the consumer. 

Secondary Packaging

Secondary packaging is generally used to group a certain amount of products together into a cohesive unit that’s easy to identify. The SKU, or Stock Keeping Unit, makes it easy for vendors to identify the movement of stock as well as inventory. Secondary packaging makes it possible to group products so that they can be more easily tracked. Smaller shipments of products are often shipped using secondary packaging. 

The packaging itself can be made up of several individual pieces including:

• The box itself
• Interior padding
• Product separators
• Reinforcement to prevent crushing or denting the box
• And so on

For most people, secondary packaging is what comes to mind when they think about packaging. Everything from the branded ecommerce packaging that you receive in the mail to the customized boxes that line the shelves at your local retail store are part of the secondary packaging level.

The individual pieces of secondary packaging can be further customized, in order to make the product more visible and easily found in a warehouse or retail store. Referring back to our cereal example, the secondary packaging would be the box that contains multiple custom boxes of cereal for storage in a warehouse before it goes onto retail shelves. Another example would be a “fridge pack” for the carbonated drinks, which is what is used to store several of the cans together and offer another layer of protection. 

Sometimes, primary and secondary packaging can overlap. For example, retail stores often receive shipments of a newly-released movie in a box that doubles as a display stand. The box serves as secondary packaging to protect the item, but it also serves as retail packaging to catch the consumer’s eye, even though the DVD case itself is how the movie is delivered to the consumer. 

Consumers will often see and interact with secondary packaging, particularly if it follows the two-in-one shipping and marketing option like the aforementioned DVDs or carbonated drinks. If you plan on using your product packaging similarly, it makes sense to consider how your product packaging design can leave a memorable impression on your customers.

Tertiary Packaging

Tertiary packaging is often known as bulk packaging or transit packaging. It’s used to transport larger numbers of goods safely and securely to their destination. Imagine several boxes full of cereal boxes arriving on pallets to distribution centers.

This kind of packaging makes it easy to handle, store and ship goods as single, self-contained units. Oftentimes, tertiary packaging consists of several cardboard boxes huddled together with stretch-wrap to prevent the packaging from being jostled and bumped around in transit. 

Consumers generally don’t see tertiary packaging, since it’s often used just to add another layer of protection to the secondary packaging and also to group larger shipments together for storage and easy retrieval of SKUs. 

Why Do Packaging Levels Matter?

Whether items are being shipped in a large group or you’re grouping together similar products for retail display, or individual items for customer consumption or use — custom packaging at every stage is important. 

On the tertiary packaging level, consumers may not see it, but that doesn’t mean you should pay any less attention to it. At every level of your packaging, whether consumer-facing or not, there’s strategy involved. Keeping your product (especially if there’s a large number of them) safe during shipping and fulfillment is just as important as catching the consumer’s eye on a retail shelf. 

Of course, it’s also understandable that you want to save money while protecting your product. The good news is that working with a knowledgeable, experienced packaging company is what often makes the difference between your goods arriving safe and sound and presenting itself as the customer’s best option, versus arriving broken, dented, crushed, torn or worse. 

Help is Here for Every Level of Your Custom Packaging Journey

Fortunately, Refine Packaging is here to help. With our extensive knowledge and expertise in all things product packaging and printing, we’re able to help you stay on budget while exploring amazing options that will highlight and position your product as the consumer’s very best option from among all of your competitors. 

From secure tertiary packaging that keeps your items secure from the warehouse or distribution center to store shelves, to secondary packaging that highlights your brand while making it easy for consumers to access the product itself, to primary packaging that puts the spotlight squarely on your product, putting it head and shoulders above the rest — you can count on Refine Packaging to provide you with consulting and fulfillment services at every step of the process. 

Even if you don’t yet have a vision for your brand and you need input on how to properly communicate it to consumers, our staff of talented graphic artists can help guide you every step of the way. Spanning many different disciplines and backgrounds, we have the skills to take your vision and transform it into a beautiful product design.

Effortlessly communicate your brand and promote your product’s unique style. It’s possible not only with the graphics and packaging design themselves, but also with the materials used in your packaging.

Eco-friendly and environmentally-conscious, rustic and primitive, elegant and modern, sophisticated and luxurious. No matter what type of impression you want to convey, Refine Packaging is able to bring it to life.

You’ve worked hard to create an incredible product. Contact us today for a free, no obligation quote on your product packaging and let our exceptional team of packaging and printing professionals help design packaging that reinforces everything you want users to know about your product and its superb performance and style. 

The post The 3 Levels of Packaging: Primary, Secondary and Tertiary Packaging appeared first on Refine Packaging.

As you explore the world of custom packaging, you’ll likely run into the terms paper grade and paper weight at some point along the way.

The terminology for paper weight and paper grades can be confusing. Sometimes it looks like you’re reading a foreign language, but don’t worry. Soon, you’ll know how to make sense of abbreviations like Cover 100#, Gloss Text 80# and 24# Uncoated just like the pros.

Without further ado, let’s dive into the different paper weight and paper grades you’ll need to understand for packaging.

Understanding Paper Weights

Paper weights help to identify the thickness or thinness of paper, and also reflects the durability for its use in packaging.

When we talk about paper weights, it’s important to note that just like many other methods of measuring, the U.S. method of determining paper weight is different from the rest of the world.

In the U.S., paper weight is determined by its manufacturing origin. The rest of the world, on the other hand, compares the weight of a single square unit of paper.

When you have the same type of paper from two different paper manufacturers – this measuring system becomes increasingly complex. Although both papers may be physically the same, the process used to make them might differ. 

Comparing Different Grades of Paper

Different grades of paper are determined by how the paper is going to be used. They include:

Opaque and Offset Uncoated Papers

Offset uncoated papers are a large volume commodity grade of paper.

This grade of paper is often used for archival purposes since the way it’s made makes it more alkaline as opposed to acidic, and that allows the paper to look newer, longer. Plus, the internal bonding between the components in the paper itself is very good and the paper itself is rather durable. 

Offset paper generally weighs anywhere from 50 lbs to 80 lbs and can be finished using a smooth finish, a vellum finish (which, despite its name, has a rough texture) or a patterned finish like linen.

Opaque paper has a similar weight but the pulp quality is better. Plus, true to its name, this type of paper has a higher opacity, which means it’s more difficult to see through.

The finishes for opaque paper include an elegant-looking satin finish, a more durable film coat, or a simple, protective thin coat.

Writing Paper

Traditionally known as Correspondence Papers or Bond Papers, this paper is most commonly found nestled within your home or office printer and is typically used for corporate letters or even hand-written notes.

You can add a watermark to this type of paper or add cotton fibers to give it more strength and a classier feel.

Text and Cover Papers

There are premium uncoated papers known as text and cover papers that are great for things like report covers, brochures and business cards. These types of papers are great for presentations and can come in a wide range of finishes, colors and patterns. 

4 Popular Paper Grades Used in Packaging

When you see things like 100# and the various coated or uncoated types, it’s easy to get overwhelmed. But there is somewhat of a secret to understanding the grade of paper.

Simply put, the higher the paper’s GSM or PT Unit, the thicker the material. The thicker the material, the more durable it is and the more weight it can sustain.

When deciding on the best paperboard to use for your stock or custom packaging, here are the 4 the most common types of paper grades you’ll likely find: 

1. Clay Coated News Backboard (CCNB)

Clay coated news backboard, commonly known as CCNB cartons, are made from a mix of recycled newspapers, old corrugated containers and a mix of other types of paper.

CCNB is often the most cost-effective and affordable option for printing, however there are some drawbacks to be aware of.

This type of packaging, due to its nature and its makeup, can absorb a lot of water, so it’s best not to choose this option if you’re concerned about moisture affecting your product. Foldable carton packaging is most often made with this type of paper.

Among paper grades, it’s not exactly a fan favorite simply because the quality isn’t as high as other types of paper grades, the paper can’t hold much weight in terms of product and it’s more affected by moisture than other varieties. Still, if you need something quick, easy and affordable, it doesn’t get much easier than this.

This type of paper often houses things like pet food, detergent, or dry goods like noodles or beans. 

2. Folding Box Board (FBB)

Folding box board, or FBB, is crafted using a combination of chemicals and mechanical material and processes to create a pulp material that’s several layers thick which adds exceptional strength and durability. Because the chemical layer of this paper is bleached, it provides an exceptional canvas on which to create high quality prints. 

This type of material is stiffer when compared to other grades of paper, but it’s a great choice for many different types of products and is often used for food, cosmetics and even pharmaceutical products. 

3. Solid Bleached Sulfate Board (SBS)

Solid Bleached Sulfate or SBS, is the epitome of product packaging.

Similar to folding box board, with SBS, the fibers are first chemically pulped and then bleached. After this process, the bleached pulp formed into box shapes. 

Since both the inside and outside of the box have a white surface, it’s an excellent option for printing in and out. You can also use high quality specialty processes on this grade of packaging, like spot UV printing, embossing and debossing, hot foil stamping and much more. 

Understandably, this type of custom packaging is most popular with a variety of industries and can package everything from food to tobacco to personal care items and everything in between. 

4. Natural Kraft or Coated Unbleached Kraft (SUS or CUK)

Known as SUS or CUK, kraft packaging is made from 100% recycled materials, making it a great choice for environmentally-conscious companies who want to embrace a more eco-friendly packaging style.

It’s an excellent option for food packaging and its fantastic strength and tear-resistant design makes it just as hardy and resilient for heavy beverages, cosmetics and more. A thin layer of kaolin clay can be applied to make the surface support even higher quality printing. 

Get Started with the Right Paper Grade for Your Packaging Project 

It’s understandable to feel overwhelmed or confused about the different grades and weights of paper and which is best for your retail packaging, not to mention the different types of finishes, applications and specialty printing options you get with your specific paper or packaging choice.

But you don’t have to navigate the uncertainty of paper grades and weights on your own. Here at Refine Packaging, we make all things packaging our business so that you don’t have to. If you have questions, aren’t sure what options to choose or would like more information on the types and grades of paper available and the pros and cons of each, contact us today for a free no obligation quote.

No matter what type of product you want to protect, we have packaging that’s fully customizable and ready to present your product in the best possible light.

We’ll take the time to better understand your project and your vision for your product packaging design, and then help you create a look that’s durable, attractive and attention-getting, so that you can concentrate on marketing and selling, while leaving the packaging design and printing to us. 

The post Understanding the 4 Most Popular Types of Paper Grades in Packaging appeared first on Refine Packaging.

You’ve created an amazing product. Now it’s time to get it into the hands of eager customers. 

You’ve made countless decisions already, but now is the moment of truth. It’s time to decide on something that could make or break your customer’s first impression about your products.

Should you choose stock packaging or custom packaging? 

It’s a difficult decision to make. Especially when you consider that:

• In a Dotcom Distribution study, over 60% of those surveyed said that gift-like packaging gets them excited about what they ordered.
• 40% of these online shoppers said they would be more likely to purchase from a retailer again if the retailer used premium packaging.

By understanding the differences and the pros and cons of stock and custom packaging, you’ll be able to confidently make this decision and give your product the best possible impression on your customers. 

Here’s what you need to know before you decide on either stock packaging vs custom packaging. 

Stock packaging is readily available packaging that’s easy to access and use right away. It’s often the default choice from shipping warehouses. Stock packaging, as its name implies, comes “as is” with little to no customization available. Since it’s not designed specific to your needs, it will have a basic and generic look and feel to it. 

You’d want to use stock packaging if you urgently need to get your product into consumers’ hands and you’re not concerned about the impression your packaging will have on your customers.

Stock packaging is fast, freely available and comes in different sizes and shapes (all of which are very broad and not specifically tailored to your product). It’s also economical, so if you’re looking for ways to save money, stock packaging just might be your solution.

Custom packaging is essentially everything that isn’t stock packaging.

Imagine that your product has a unique size or shape. You may want retail packaging that’s specifically designed to highlight the product’s shape and house the product snuggly and securely. Custom packaging can help you do just that.

In fact, if all you want is a plain white box, although it sounds broad and generic, you’d be surprised to learn how few suppliers of stock packaging actually have the exact box dimensions you need.

Custom packaging is also available in a wide range of shapes and sizes and you can customize nearly every facet of it – and not just in terms of the design, but also added printed effects that make your brand and product truly stand out and leave a lasting impression.

Even if you don’t want all the “bells and whistles” that custom packaging can offer – customizations like matte or gloss lamination, foil stamping, embossing or debossing or spot UV  – it may still be a good idea to opt for custom packaging.

Just search for “unboxing” on YouTube and you’ll see how much people obsess over beautiful custom packaging. In a recent Dotcom Distribution study, 50% said gift-like or branded packaging makes them more likely to recommend a brand to others.

Suffice it to say, custom packaging is an easy way to spike interest in your products and build excitement around your brand.  

Stock Packaging vs. Custom Packaging: When To Use Each One

With all these pros and cons for stock packaging vs. custom packaging, you may find it difficult to truly narrow down when you’d want to use each type of packaging.

To make it easier for you, we’ve compiled a list of instances where one option is likely better than the other. 

You should use stock packaging when: 

• You want to test out different marketing options and don’t want the expense and time of custom printing until you’re ready for it.
• You’re a startup on a tight budget and are looking for an economical way to conduct market tests or do other promotions.
• You’re faced with production shortages and need to get the available product out the door ASAP. 
• You’re preparing trade show samples to be given out to attendees.

As you can see, the name of the game with stock packaging is that it’s quick, cheap, easy to obtain and almost certainly available. 

You should use custom packaging when: 

• You have a luxury product and you want to create a sophisticated look.
• You want to take full advantage of custom box design or shape options for your product.
• You want users to unbox your product on social media and share their reactions
• You need or want packaging that’s unique and beyond the ordinary and you’re prepared to pay more for nearly limitless customization options.
• You have a large volume of printed packaging needed and you want every facet of your packaging production to be tailored to your specific needs. 
• You have a subscription box service or an ecommerce type of service and you want to highlight your product in a unique way.

Stock packaging may be cheap, fast and easy, but you lose a lot of things you may not have even considered when you choose to go with out-of-the-box packaging.

With custom packaging, you open up a whole world of design and personalization benefits. There are flexible printing techniques and tools that you can utilize to deliver an impressive customer experience. Every angle of the package, and even the material itself can be printed, embossed, highlighted, glossed and so much more in order to make it stand out from the competition. 

The Bottom Line on Stock Packaging vs. Custom Packaging

As you can see, the “debate” on stock packaging vs. custom packaging is really not much of a debate at all. When you consider the stark differences between what stock packaging brings to the table, and what you can have with custom packaging – there really are times when one is a better option than the other. 

When it comes to choosing custom packaging, it’s vitally important to do it right. At Refine Packaging, we have years of experience creating custom packaging for all types of products, sizes and configurations.

The world of custom packaging can be confusing and overwhelming for a first time product designer, and even if it isn’t your first product design rodeo, it’s still nice to have a knowledgeable team of experts on your side to help guide you and provide advice.

Whether you already have an idea in mind or you’d like suggestions, our team of artists is trained in a variety of styles and mediums, and can maneuver easily across different graphic styles to create a look that accurately captures your idea and your product in one complete design.

The team at Refine Packaging is eager to help you take the next step with your custom packaging and walk you through the process so that you can have packaging that perfectly exemplifies and embodies the best features of your product and your brand.

Contact us today for a free, no obligation quote on your custom packaging needs and we’ll work with you to create a look and a package that brings together the very best of your brand personality, social appeal, and quality product design to create a look that is unmistakably your own. 

The post Stock Packaging vs. Custom Packaging: What’s The Difference? appeared first on Refine Packaging.

Sustainable packaging is booming, with no signs of slowing down.

People are aware of the environmental impact of packaging and waste. It’s becoming increasingly important to take a more eco-friendly approach. In a recent DotCom Distribution study, 57% of respondents said that green packaging is important to them.

For business owners looking to make a great impression with their custom packaging but still minimize waste, kraft paper is an excellent and versatile choice.

Kraft paper offers numerous benefits and can be a more environmentally-green option for your business.

So, what is kraft paper? How is this paper made? How can you use brown kraft paper packaging in your environmentally-conscious business? 

Let’s take a closer look. 

How Kraft Paper Is Made

Kraft paper was invented in 1879 by an individual named Carl Dahl. He chose to give his newly created paper the name “kraft” – the German word for strong. 

You may not realize it, but kraft paper packaging is already a well-known part of the printing and packaging world. From serving as a strong filler in the packages you receive, to eloquently wrapping gift boxes, it’s hard to find a package that doesn’t use this durable paper in some form or fashion when it comes to sustainable and eco-friendly packaging.

But how did it come about?

Paper involves a process that converts wood into wood pulp and from there, into paper. Wood pulp is held together by lignin, which is a type of cellular structure, and cellulose. Lignin, owing to its structure, doesn’t exactly make a good paper, but cellulose does. That means there needed to be a way to separate the lignin from the cellulose.

What Mr. Dahl discovered was that if he “cooked” the wood chips in a chemical composition made up of sodium sulfide and sodium hydroxide, those tough lignin fibers would break down and break apart from the cellulose. From there, the remnants could be screened through a mesh to remove larger pieces and then made into paper.

Now, although this cooking process separates the lignin and the cellulose, it doesn’t remove them all entirely. This is how kraft paper remains so strong. There’s still lignin content in the paper pulp mixture, and there’s also a lot of sulfur in the mix. Both of these components together add to the strength of kraft paper.

The color of brown kraft paper comes as a natural product from the wood pulp. If kraft paper were to be bleached, that would not only increase the cost to produce it, but would also weaken it by destroying those fibers that make it as durable as it is. It is, however, possible to have bleached (white) kraft paper that is stronger than conventional paper. Bleached kraft paper is also important if you want to protect your product packaging against yellowing over time. 

So what are the benefits to using kraft paper in your product packaging? Here are just a few reasons to consider making kraft paper your packaging of choice.

Benefits of Using Kraft Paper in Custom Packaging

Now that you better understand how kraft paper is made, the next question is, what can it really do for your business? 

Kraft Paper Adds Natural Beauty with a Timeless Appeal 

If you’re looking for a great way to position your business as a natural champion of the environment, kraft paper has a simple, appealing and primitive look that can help you achieve that goal. It stands out from mass-produced paper packaging simply because of its more rustic nature. 

Looks aside, kraft paper also doesn’t add much in terms of weight to your custom boxes, but still surrounds it with excellent durability. That means that you get the benefits of a package that can withstand rougher handling and shuffling, but won’t cost much in terms of shipping rates. 

You’ll also be glad to know that kraft paper is recyclable. Kraft paper degrades naturally and has no negative environmental impact. It degrades within just a few weeks, but it can also be saved and reused, helping to maintain your brand credibility as a company that’s forward-thinking and that cares about their impact on the environment. 

Kraft Paper is Extremely Durable for Custom Kraft Boxes

The way that kraft paper is made helps to make it inherently strong. But it can be made even stronger and better by coating the resulting pressed paper with PE or polyethylene. This also helps protect the kraft paper from moisture and bacteria, although one downside is that this coating does affect the ease with which it is recycled. 

If you need even greater durability, you can use several layers of kraft paper to create even tougher kraft boxes for your packaging. 

Brown Kraft Paper is Good for the Environment

Unlike the processing that occurs with regular paper manufacturing and printing, kraft paper follows a much simpler process using fewer chemicals. In addition, these chemicals can be recovered, recycled and reused without any loss in quality. The remaining byproducts of the kraft process are tall oil and turpentine, which can be used in the manufacturing processes of other items. 

Kraft paper can also be made from different kinds of wood. Certain woods like bamboo and pine aren’t often used in the making of traditional paper. Pine is too resinous and bamboo takes a long time to be correctly processed which makes it cost prohibitive for most ordinary uses. However, both of these types of common woods make excellent use of the kraft paper process.  

In the end, brown kraft paper and the process that goes into making it is self-sustaining and for those parts that aren’t, they can be reused, making it a great option for businesses that need durability but still want to highlight their green manufacturing processes. 

How to Get Started with Kraft Paper Packaging

As you consider kraft paper among the different types of packaging and printing possibilities like folding cartons and corrugated boxes, it’s understandable to have questions. Fortunately, you have a knowledgeable, experienced ally on your side who can help you navigate the printing and packaging process from start to finish.

At Refine Packaging, we know that you have many different options for how to prepare, print and package your product. We also understand that you want to keep costs low but still create an affordable, beautiful presentation for your customers.

If you’re interested in using kraft paper for your company’s custom kraft packaging boxes, talk to us first. We have the skills, expertise and equipment necessary to take your product packaging from a conceptual vision to a finished product ready to be unboxed by your customers.

Everything we do is meant to enhance the quality and perception of your product, so no matter what you’re selling or what industry you’re in, our knowledgeable packaging professionals can work with you to better understand your vision and make your packaging come to life.

Whether you want to create a natural, environmentally-friendly and attractive package or you want to showcase your forward-thinking, eco-minded mission, kraft paper is a great way to show off the simplicity, “homemade-ness” and organic qualities of your product, all in one  concise packaging design.

Who knew simple kraft paper was capable of so much? 

Get Your Free Estimate for Your Product Design and Packaging

Contact us at Refine Packaging today to learn more about this or our many other packaging options for your product.

We also have a team of talented artists on staff who can properly design your sustainable packaging in a way that accurately and fully reflects your brand, your story and your business perception so that your product stands head and shoulders above that of your competition. 

Reach out to us today for a free, no obligation quote and to learn more about our comprehensive packaging and printing design services.

The post What is Kraft Paper? Discover the Unique Eco-Friendly Benefits for Durable Packaging appeared first on Refine Packaging.

Think about the last time you visited a bakery.

Chances are, the boxes have an opening on top that lets you see the delicious sweets inside the box – before you ever open up the box and dig in.

If your product is big on visual appeal, window patching might be exactly what you need.

So what is window patching? What does the window patching process look like in custom packaging?

While window patching is often used in packaging for products like toys and snacks, but can be used for any type of product. A window can also be used to showcase the high quality and craftsmanship of higher-end luxury products.

Adding window box patching to your retail packaging is one of the many choices you’ll need to make as you decide how you want to present your product to consumers. 

PET and PVC: Common Types of Window Patching Films

The most common types of film used in window patching are polyethylene terephthalate (PET) and polyvinyl chloride (PVC).

With PET film, the plastic is shaped into the style you want and then dried to offer greater protection. This makes the film virtually impossible to tamper with and gives it excellent protection even against regular handling. PET film is light, which may leave it prone to scratching, but it holds its own against external pressure while protecting the product within. This makes it a great option for retail and consumer-facing products, particularly food. 

PVC film, on the other hand, is even more resistant to scuffs, wear and tear. It also weathers the elements well and holds its own against moisture. When exposed to UV rays, however, PVC film can degrade and discolor. This can also create an odor and rippling within the packaging. Due to the odor, we do not recommend this type of film for packaging food or snacks, but we do recommend it for products that need added protection against heavy or frequent handling. 

What Other Kinds of Window Patching Films Are There?

PET and PVC film are by no means the only two kinds of window patching films out there. Depending on your product and the custom window boxes you need, there may be other films that may be better suited to your needs. For example: 

• Polyolefin is ideal for boxed goods and as a shrink film.
• Polyethylene is best for frozen foods.
• Glassine is for products that have high grease content.
• Polypropylene is best for baked goods and candy that use bakery boxes with a window.
• Laminated foil is best suited for products that are sensitive to air or light.

Two Types of Windows: Rigid vs. Flexible Windows 

Cellophane window packaging (also called windowing) is more common than ever and is a great way to make your product stand out from your competition. These types of windows give your customers the opportunity to see your product exactly the way it is before unboxing – with nothing to hide. This in turn helps build credibility and trust in your brand, as well as paving the way for an engaging user experience.

Cellophane windows are generally used for food and beverage, but are also common in cosmetics and retail products. Think of the last product you purchased that had a small window where you could see the luxurious or delicious contents. It was an instant reflection of quality, wasn’t it? 

With these types of windows, you have two options: rigid windows and flexible windows. Flexible windows are the most affordable and are made from polyester film. In addition, this type of film is eco-friendly and can be recycled. Because of its flexibility, it’s great for oddly-shaped packages or packages with curves. 

This type of cellophane packaging is also approved for food contact because it is designed to meet the most exacting standards of the top food safety organizations. And although flexible windows are affordable, rigid windows also offer several benefits.

Rigid windows are generally made from a hard plastic resin and are typically used on high-end or luxury products. They’re also commonly found on pharmaceutical products and some cosmetics.

Larger packages where you want a wide window area can also be better served and protected with rigid windows. They’re a great way to showcase your product in its entirety, show it with crystal clarity and protect it with far greater strength than other forms of window box patching. 

The Window Patching Process

The window patching process is made possible by a machine that is specifically designed for that purpose. With this machine, a reel that contains a specific type of plastic film, like PET or PVC applies windows to the product. Using electromagnetic energy, the product passes through the reel quickly and the film is applied to the packaging paper.

Generally the plastic film instantly sticks to the material without needing any drying time. This greatly speeds up the process since the package is ready once it completes its run from the window patching machine. 

Considerations For Choosing the Right Type of Window Box Patching 

There are some things you’ll want to keep in mind to help you better decide which type of window patching is right for you. Here are a few tips to make your choice easier:

Window Size

First, it’s important to consider the size of the window you want to have on your packaging. Larger windows are more prone to breakage, scratches and tears, so you’ll want your film to be strong. Smaller windows could be best served by thinner films. It’s important that when preparing the design for your box, you leave enough room for the film to be glued or pressed into the packaging material. 

Strength and Sturdiness Levels 

Luxury products like pharmaceutical products and cosmetics will need a higher level of stiffness and sturdiness to help properly protect them while delivering impeccable clarity to showcase the product within. These products typically have high gloss lamination as well to position them in such a way as to be more eye-catching for the user.

Higher end products also need great tensile strength to prevent them from tearing or being broken during shipping. This high need for structural integrity means that production will be slower and thus increase the cost involved in manufacturing the packaging. 

Exposure to the Elements

Finally, if your product will be exposed to the elements, including heat, moisture or freezing temperatures, it’s important to keep in mind how that may affect the contents within. The right packaging film needs to be stable enough to handle this.

Baked goods, for example, may still be packaged while warm, which creates a steamy, high-moisture environment. They can then be flash frozen to protect the integrity of the product itself. Inferior packaging could make this process a disaster in the making, which is why it’s so important to entrust your product packaging to the experts. 

For more print finishing options, read up about spot UV, soft-touch coating and lamination and varnish for custom packaging.   

Have Questions About the Window Patching Process? 

It’s easy to feel overwhelmed about all of the choices available in window patching alone, let alone how it fits in with your overall plan for your product packaging design. Let the experts at Refine Packaging help you make your decision with confidence.

Whether you need a large, clear and high-visibility window to showcase all the beauty and style of your product, or you want something smaller and more environmentally friendly that can be recycled, we have your needs covered.

Contact us today and let us know more about your product and your vision for its packaging design. Don’t have a packaging design in mind? We have proficient artists on staff who can help conceptualize your idea and transform it into a breathtaking design you’ll love.

Get a free, no obligation quote on your product packaging and window patching needs from the experts at Refine Packaging today.

The post What is Window Patching? Understanding the Window Patching Process in Printing & Packaging appeared first on Refine Packaging.

Carton packaging is an incredibly popular choice for product packaging.

Everything from cereal to cosmetics comes in carton packaging, in part, due to the level of customization for a wide range of box sizes and specifications that is nearly unmatched.

But what exactly is carton packaging? How did this type of packaging get so popular worldwide? What is it used for now?

Let’s take a closer look at carton packaging and how it all works to deliver impressive structure, branding and stability to your retail packaging. 

Carton packaging is also commonly referred to as carton boxes, folding cartons, paperboard cartons and paperboard boxes.

The History of Folding Cartons: Who Invented Carton Packaging?

Foldable carton packaging was invented by Charles Henry Foyle in the late 1800s, an Englishman who created the product we know as the carton today. It was essentially a piece of paper that was cut in such a way that it could be folded into a custom box. Although incredibly innovative for its time, carton packaging still lacked a lot of the features we know and love today.

For example, although it could be folded into a box shape, the ends still needed to be held together tightly, so it was common to use tacks and strings to hold the carton boxes together. This was expensive, not to mention labor-intensive. What’s more, such boxes were difficult to produce, so carton packaging like this was usually only used for valuable luxury items like jewelry. 

Fortunately, carton packaging came into the limelight in 1879, when Robert Gair realized that his printing press could cut through the carton material and allow for mass production of carton packaging. Food and snack companies realized that the foldable boxes greatly extended the shelf life of their products, and were among the first to regularly use such materials. 

The first snack food company to adopt the use of carton packaging was the National Biscuit Company, better known today as Nabisco. 

How Is Carton Packaging Used Today? 

Today, carton packaging has found a reliable home among store shelves around the world. When deciding on your product’s box design and presentation, there are many reasons to consider using carton boxes, including: 

Eco-Friendly Packaging

In this day and age, consumers do their best to be responsible stewards of the planet. That means buying and using packaging made from recyclable materials like Kraft paper.

Cartons are made with more than 75% paper that comes from sustainable sources and is harvested using responsible practices. This means choosing carton packaging boxes for your product packaging needs is an eco-friendly choice that reflects well on your brand and your company. 

High Shelf Appeal

Beautiful packaging has what we call “high shelf appeal”.  Properly designed, structured carton boxes help solidify your brand in the consumer’s mind as one of quality and consistency. What’s more, they provide ample space to showcase your brand message.

Tell your story through your product packaging design, highlight the benefits of your product, present a promotion or even showcase your social responsibility endeavors by using eco-friendly packaging. The choices are endless! 

Common Types of Carton Packaging Boxes

There are several distinctive types of carton packaging, each with its own benefits depending on your needs. Companies turn to high quality paperboard carton packaging to protect, store and showcase their food, beverage, cosmetics, supplements and so much more. Here are just a few of the many different types of carton packaging that are commonly used in retail packaging. 

Strength Packaging

Strength packaging offers solid, reliable structural design to help protect your product from being compressed. But don’t let its rigidity fool you, high strength packaging is still fully customizable and printable so you can feel free to unleash your creativity with this durable packaging. 

Foldable Cartons

The original and still one of the most popular types of carton packaging. Flexible enough to be folded by hand if you only have a few small batches, or process through high speed automation for larger numbers, foldable cartons can be completely customized and designed for all your promotional needs.

Multipacks

If you’re selling several of an item together, multipacks are an excellent way to keep each item secure and stable while protecting the entire lot in one complete package. Often used for things like canned goods, cereal, yogurt and other types of food. 

Hybrid Packaging

Hybrid packaging blends different features of different types of carton packaging to create a “best of both worlds” combination. 

Looking for more types of carton packaging? Read our ultimate guide to carton boxes for a deeper look into folding cartons.

Other Benefits Carton Packaging Offers

It’s worth noting that like any type of packaging, carton packaging offers an opportunity to increase the perceived value of the product inside.

Although we’re no longer tying up or tacking down our cartons, and they’re no longer reserved for jewelry or other expensive items, carton packages have nevertheless surged in popularity and continue to be popular today with some adjustments, such as being made with eco-friendly materials. 

What’s more, foldable carton packaging can be shaped into any type of design. It doesn’t necessarily have to be a box. This makes it a great way to add a unique flair or creativity to your product to set it apart from all of the other boxes out there. Taking advantage of the large printable area on carton boxes is a smart idea that is commonly used in cosmetic packaging design, and is a great way to showcase the benefits of your product.

Build Your Brand with Carton Packaging 

At Refine Packaging, we understand that not everyone is a packaging expert.

Packaging is our passion and we strive to create printed designs that are the perfect match for your product. Our staff of graphic artists spans a variety of styles, so even if you don’t have a design in mind, we can create something that perfectly encompasses and reflects your brand, your story and your message, as well as the things that set you apart from your competition.

We create memorable, beautiful and stylish packaging for a wide range of industries, products and businesses large and small. If you’re thinking of choosing paperboard boxes or you’re not sure what type of custom packaging is right for your specific needs, talk to us!

We have decades of combined experience and bring our detailed industry knowledge to work for you in a way that’s easy to understand and will get your product in the hands of consumers faster. 

We also offer a variety of styles and printing processes that can make your packaging look extraordinary. From UV coating to foil stamping or different types of glosses, there are a variety of factors you’ll want to consider when choosing the right type of packaging material and design for your specific needs. But that doesn’t mean you have to do it all alone! 

Now that you’ve read about carton packaging boxes in more detail, why not contact the printing and packaging experts at Refine Packaging for a free, no obligation estimate on your printing and packaging needs? 

Let’s work together to create a style that’s uniquely your own, with packaging that exceeds your expectations. 

The post What is Carton Packaging? Folding Carton Packaging Explained. appeared first on Refine Packaging.

Corrugated packaging is everywhere.

More than 95% of all goods consumed in North America are packaged and transported in corrugated packaging. Corrugated boxes are universal – both at work and at home. A true staple of the retail world.

But what exactly is corrugated packaging? Why is corrugated material so commonly used? And when should corrugated packaging be used? 

Who Invented Corrugated Packaging?

Corrugated packaging as we know it goes back more than a century, born from the need to package and store goods for a longer period of time.

In 1856, Healey and Allen, two Englishmen, secured a patent for the first known use of corrugated paper. Using two fluted rolls, corrugated paper was fed through a hand-cranked machine, creating fluted paper lining that could be placed in hats.

But corrugated paper for hats is one thing, and corrugated packaging for transporting products is completely different. An American named Albert S. Jones is responsible for this combination, and was the first person known to use corrugated paper to wrap fragile items like bottles and other easily breakable goods in a similar way that corrugated packaging is used today. 

How is Corrugated Packaging Made? 

The process for creating corrugated packaging hasn’t changed much since its humble origins in the 1850s.

With corrugated packaging, two sheets of flat paper known as liners or linerboard, are glued to a corrugated inner material called fluting.

Together, these distinctive layers are stronger than they would be if they were used separately. If you look closely at corrugating packaging, you can see a type of weave pattern. This is what adds structure and stability to the packaging. 

Different fluting can be used to make different sizes of arch in the material, creating an end result that is structurally superior to many other types of packaging and is a great option for products that need to be handled and packed carefully. 

Curious for more details? We dive deeper into the corrugated packaging process and different flute grades in our ultimate guide to corrugated packaging.

Why Use Corrugated Packaging? 

There are several reasons why you might consider using corrugated packaging as your product packaging of choice: 

• Stronger than Cardboard: Safe, sturdy and protective, corrugated boxes are stronger than cardboard, so you can feel confident that whatever you put inside will stay safe and sound. Corrugated packaging is also crush and pressure-resistant. 
• A Wide Range of Sizes: Corrugated packaging is available in a wide range of sizes. Although it’s strong, it’s also lightweight, making it a great fit for nearly any type of product that needs to be protected, but without the added weight. 
• Can Be Broken Down and Reused: Corrugated boxes can be broken down and stored easily or transported without affecting the structural integrity of the packaging. 
• Good for the Environment: The packaging material itself is made from recycled and renewable materials, such as Kraft, making them an eco-friendly packaging option that consumers will appreciate. 

Corrugated vs. Cardboard Packaging: What’s the Difference? 

With the incredible surge in online shopping (COVID19 notwithstanding), customers expect their packages to be delivered safe and sound, with the contents in good condition.

Packages that arrive damaged, crushed, or torn open leave a bad impression when unboxing. That’s why it’s so important to consider what level of strength and stability you need in your packaging.

Corrugated packaging and cardboard packaging are two of the most popular types of boxes, but it’s important to understand the difference between them so you can decide on the right balance of protection for the product inside. 

Cardboard Packaging

Cardboard, also known as carton packaging, is made from thick paper or paper pulp which is then crafted into small packages or even material to help bolster the structure of lesser materials so that the contents won’t lose their shape.

Cardboard is inexpensive and easy to use as part of most shipping strategies, but it also may need additional packing material to keep the contents safe from being crushed, or being damaged by the elements. 

Corrugated Cartons

These are made up of several layers of material that are stronger together than they would be on their own. An inside liner and an outside liner are filled in the middle with a fluted material that helps solidify and strengthen the entire piece.

Corrugated cartons perfectly balance strength and lightness of weight, so they’re perfect if you need to ship a variety of products carefully. In addition to their structural strength, they’re also resistant to moisture and sudden changes in temperature.

Of course, no container is fully impervious to being crushed or being exposed to rain, sleet or heat for a long period of time, but if you want the added confidence that your product will arrive securely, corrugated packaging is a great option. 

Learn more about folding cartons with our ultimate guide to carton packaging to better understand the differences between corrugated and cardboard.

When To Use Corrugated Packaging

Corrugated packaging is best for products that need to be transported from a warehouse, to a processing center and onto a delivery vehicle. With so many people and machines handling the package, it needs to withstand being shuffled, slid, tossed and even dropped. If you want to add in an extra barrier of protection, you can wrap the interior product with additional cushioning for added security and peace of mind. 

Corrugated boxes are also a great choice if you want full customization control over your packaging design. You get all of the benefits of a large design area like with cardboard, except the added strength and durability. Additional features like custom opening folds, flaps, die-cuts and embossing or debossing are just a few of the many options you can add to create a unique design without worrying that the process will mar the product within. 

If you’re selling food, corrugated packaging is a must. Not only is corrugated much more sustainable and hygienic, but with so many people turning to online grocery shopping and delivery, companies are choosing to insulate their corrugated packaging for even greater protection to help seal in the temperature, especially for perishable goods. 

Choose a Trusted Corrugated Packaging Box Manufacturer

At Refine Packaging, our decades of combined experience, coupled with our deep knowledge of the custom packaging process across a variety of industries allow us to provide you with full-service packaging design and printing services.

From choosing the right packaging material for your product, to designing a look that captivates your audience and elevates your brand, trust the professionals at Refine Packaging to deliver an end result that’s so powerful and so compelling, you’ll want to buy your own product!

If you’re interested in learning more about how corrugated packaging may be the right choice for your packaging and shipping and fulfillment needs, or you’d like to consult with us on crafting the perfect design to showcase your product, we’d be delighted to work with you.

Even if you’re not sure what type of packaging you need for your product, get in touch with us. Our experts will take the time to understand your vision and your needs and work with you to craft packaging that perfectly expresses all of those points in one artistic creation.

Contact us today to learn more about our extensive printing and packaging services and get a free, no obligation quote for all your custom packaging needs.

The post What is Corrugated Packaging? How Corrugated Packaging is Made & When to Print with Corrugated Material appeared first on Refine Packaging.

When it comes to printing materials, it’s common to see things measured in units like GSM or PT. 

But what do these unit systems actually mean? And what are their implications for your packaging and printing? 

Understanding the difference between the PT and GSM unit systems will help you better evaluate the weight and thickness of the paper or material you choose to print on. 

Knowing this will impact the printing options you choose and will help you determine how to find the right balance between durability and “printability” when it comes to your custom packaging. 

The Meaning of PT and GSM in Packaging and Printing

PT stands for The Point System while GSM stands for Grams per Square Meter. 

Both of these units of measurement are used to measure how thick stock is. Stock can be paperboard, cardboard or other packaging material. It’s used in folding cartons as well. The weight of the paper also plays a role and is measured in reams. One ream equals 500 sheets of uncut paper (where the paper is at its original, uncut size). You’ll often see paper noted as 80 lb or 80#, which means that one ream of that paper weighs 80 pounds. 

In order to understand the point (PT) system, it’s important to know that a point equals .001 inches, so 10 points would mean that there is a stock thickness of 0.01 inches.

GSM is the metric equivalent of points, but is based on the metric system rather than on inches. As you consider different paper levels, it’s important to understand that the thicker a packaging material is, doesn’t necessarily mean that it will be heavier. With that being said, the higher the GSM, the thicker the paper will be. 

So, how do you determine the weight of a particular printing material?

By looking at the material itself. It helps to know what different GSM weights of common materials are so that you can have an idea of the thickness of the packaging you need. 

Common GSM Paper Measurements

• 35-55 GSM: Newspaper, very thin and delicate.
• 90-100 GSM: Printer paper, more durable than newspaper but definitely not impervious to being handled. 
• 120-140 GSM: Posters and bulletins, can withstand the elements more but can still deteriorate if exposed to them constantly over time. 
• 210-300 GSM: Magazine covers, better suited to maintaining their form even if they are bent. 
• 350-400 GSM: Most popularly referred to as card stock, this thick material is often used to print invitations and business cards and is commonly used for retail packaging as well. 

Converting Between the GSM and PT Unit System

GSM is, at its core, the metric version of the PT system and both are used to calculate thickness between each other.

However, the GSM system takes the stock weight into account, but the PT system does not. There are, however, conversion charts that simplify this process and we can convert to and from GSM to PT and vice versa if need be.

Below is a rough GSM to PT conversion chart  to help you understand how the conversion process might look in your unique scenario.

It’s worth noting that since most of the world uses the metric system, GSM is more common overall, however we’re able to work with both systems interchangeably. 

How to Compare Paper Weights and Thicknesses

The US-based system can be more confusing than the metric system, but to help make packaging uniform between the different systems, the U.S. version takes into account the weight of the uncut paper (the “basis weight” of the ream). So if you see paper marked with 92#, you’ll know it’s rather thin compared to paper with a weight of 230#.

Why does knowing the weight of paper (or other material) matter, anyway? 

You probably don’t think much about the mailers that come into your home every day – until you’re suddenly faced with paper terms like bond, text, book, cover, tag, index and more. But the differences between different sizes and styles of paper are actually a good thing.

Paper has been around for so many centuries that mankind has experimented with all kinds of creative ideas to make it durable and longer lasting. It also means that tried and true methods can be put to work right away to make your packaging stand out from the competition. 

What Do These Different Unit Systems Mean for My Product Packaging? 

Deciding between points and grams per square meter is just one of the decisions you’ll need to make when you weigh the pros and cons and differences of different types of packaging materials.

Understanding how thick and how heavy you want your packaging to be will not only affect its durability but also the way it’s printed and the features you can use. Some packaging materials will have a smoother surface, which makes printing on them easy. Others are rougher and more coarse which improves their durability, but also affects how easily different printing processes can be achieved.

At the same time, the packaging has to be durable since it needs to protect its contents while showcasing them accurately and in a way that makes the package stand out. 

Is it possible to have a package that’s truly the “best of both worlds” – something that evokes quality while maintaining durability as it goes through the printing, labeling and shipping process? The answer is yes! 

Speak with a Packaging Expert To Help You Decide on GSM vs PT Unit System

Considering different types of paper weight, thickness, GSM and PT systems and how to choose the right balance between durability, thickness, “printability” and other options can be overwhelming – but that doesn’t mean you have to make that decision alone. 

At Refine Packaging, we know that the design, printing and packaging world can be a confusing place to navigate, which is why we’re here to walk you through the process from start to finish and help you enjoy an incredible end result that perfectly positions your product. 

We take great pride in taking the time to understand your vision and your goals for your product. Whether it’s standing out with a unique design to separate your product from the crowd, or giving your product a sophisticated and elegant look that was born for unboxing, we have the know-how, expertise and experience to make the end result truly surpass your expectations. 

We welcome the opportunity to help you across all aspects of your product’s packaging design. Even if you’re not exactly sure what you want, we have graphic artists on staff who can help bring your vision to life. Once you’ve decided on the design, we can help you choose the right packaging material that helps to protect your product while showcasing it perfectly from every angle. 

Plus, we can also help your product stand out in more than just the visual sense. Using the very latest in printing technology, we provide options that are both eye-catching and sensational to behold. From spot UV printing and foil stamping to soft touch coating and lamination that protects and enhances the value of your product, everything we do is done with satisfaction in mind: both yours and your customers. 

Interested in learning more about our comprehensive packaging design and printing services? Contact us today for a free, no obligation quote. We’ll take the time to answer any questions you may have about GSM versus PT in print or any other questions you may have about the packaging process.

We know you’ve worked hard to create a product that’s truly extraordinary – now it’s time to choose custom packaging that’s equally as incredible! 

The post GSM vs. PT Unit System: Main Differences and Which is Best for Printing appeared first on Refine Packaging.

Have you ever wondered how some packaging gets its golden shine?

Or what gives some custom boxes a classy and elegant look that others are missing?

Foil stamping might be the answer you’ve been looking for.

Foil stamping is a unique printing process where heat, pressure, foil and metal come together to create unique designs and optical effects.

The foil can be any color, but usually metallic foils, like gold and silver are used. Foil rolls, like paper, are available in matte and glossy finishes. 

Foil Stamping: A Brief History

The foil stamping process has its roots in ancient Egypt, where gold was beaten with a hammer until it was extremely thin, and then applied to papyrus to add luster.

As you might imagine, this process was labor intensive and only reserved for the highest quality written records. Even throughout the beginnings of recorded history, things like gold leaf were typically reserved for royal or religious texts.

After the invention of the printing press, foil stamping used hand-set lettering or dies that were custom engraved. Because the process was so evolved, foil stamping was only used for book covers and literary works.

For example, if you wanted to print gold text on a book cover, you had to use separate fonts that used brass or lead type and then assemble the text by hand, one letter at a time, on a custom-engraved die. Once the text and the die were assembled, it was fed into the press which then printed the metallic foil sheets stamped into the book cover.

Modern foil printing came about in the early 1900s. In Berlin, a master bookbinder developed hot-stamping foils in the late 1800s. In England, atomized gold was used on thin sheets of polyester film. The popularity continued well into the 1950s and 1960s. 

The Foil Stamping Process in Printing and Packaging

Commonly known as hot foil stamping, foil stamping is similar in technique to letterpress and engraving, where pressure is used to apply color to paper.

When the design is finalized, metal plates are created for each individual color foil in the shape that’s needed. Then, the dies are heated. Pressure is applied to seal the foil to the paper or packaging material and then the press is run multiple times to apply each color individually.

If you want a raised or embossed effect, another die may be used to create that look to finish up the project. 

As you begin to explore the idea of using foil stamping in your printing, consider how your decisions about matte or gloss lamination, embossing and debossing and UV coating will influence the overall appearance of your packaging.

Common Types of Foil Used in Foil Stamping

There are several different types of foil that can be used to give different optical effects to the packaging, including: 

Metallic Foil

When you think of foil stamping, this is likely the type of foil you’re thinking of. Metallic foil, also known as metalized foil, makes your text or area have a shiny, metal-style look. It’s great for adding a touch of luxury, especially through the use of gold or silver foil as a finish. 

Pigment Foil

Pigment foil is similar to metalized foil, but does not have the metallic look. They are available in a wide range of colors and are available with matte or glossy finish, which can make them undoubtedly eye-catching or add a touch of luxury and softness

Holographic Foil

These types of holographic foils create a sort of rainbow effect in 3D. You’ve seen this type of foil at work in collectibles like baseball cards or other trading cards, or even on promotional materials. 

Other types of foil – such as pearl foil, effects foil and scratch-off foil – are less commonly used, but have well-known use cases, such as wedding invitations or lottery tickets. 

Traditional Foil Stamping

Now that you understand the different types of foil stamping, it’s time to move on to the actual methods involved.

Foil stamping can be done in two ways – traditional foil stamping or digital foil stamping.

With traditional foil stamping, the design is edged onto a metal plate. This metal plate is similar to a regular die, except its particular use is for foiling. It’s similar in function to a rubber stamp. The die is headed and a layer of the foil you want to use is placed between the die and the surface below it. The die is then pressed down onto the surface which causes the foil to bond to it in the shape of the design that was on the metal plate.

For designs that use several types of colors of foil, foiling dies need to be created for every color and the packaging material has to run through the machine several times (one for each color) so that the final design can be produced.

It’s also possible during this time to apply other effects to the foil stamping such as an embossed edge or a raised look so that the finished product stands out even more, not just visually, but with a tactile sense as well. 

Digital Foil Stamping

Also called digital foiling, digital foil stamping follows a similar process as traditional foil stamping, but rather than using pressure to bond the design to the product packaging design with a metal die, a digital printer uses a specific type of foil that adheres to the surface of the design. This means that there’s no need for multiple passes of the material into the printer for packaging design that uses several foil colors or patterns. 

One particular method is not necessarily better than the other since both can be used to create the type of effects that you want on your packaging. Should you have questions about the specific intricacies of different foil stamping processes, we’d be happy to elaborate and guide you on the one that’s right for your needs. 

Benefits of Foil Stamping

Foil stamping offers a number of benefits for your retail packaging. 

First, your product packaging will most assuredly stand out from the competition. Metallic foil or colored foil adds a touch of eye-catching brilliance and beauty to any package and gives it a luxurious style.

Combine that with other effects like raised or embossed designs and you can see how the packaging can take on a whole new level of sophistication.

In addition, foil stamping is versatile. It’s not just reserved for metallic lettering, although that is one of the most common options. In addition, hot foil stamping is durable and resistant to moisture and scratches. It can be used on different types of stock (think corrugated boxes or folding carton boxes) and still retain its luster.

Hot foil stamping is a great way to stand out and add a touch of elegance, with either bright and eye-catching gloss, or more subdued with matte style foil stamping.

Ready to Use Foil Stamping in Your Packaging?

If you love the allure and uniqueness of hot foil stamping and you’re interested in using this time-honored tradition to add refinement to your packaging, contact us today for a free, no obligation quote and consultation.

At Refine Packaging, our experts have years of experience and know-how in creating a wide variety of packaging products that leverage many different types of foil stamping and printing to ensure that your product packaging perfectly captures and conceptualizes your brand, your message and so much more.

Let us put our extensive experience to use in helping you magnify your product packaging with exquisite hot foil stamping and many other types of printing to captivate and compel your audience to buy. Rely on our expertise in helping thousands of brands large and small with all of their product packaging needs.

Not sure what type of design you need? We have a variety of talented artists on-staff that can perfectly capture your vision and what you want your brand to convey to your target audience. Contact us today to learn more about working together and let us show you the power of premium packaging. 

The post What is Foil Stamping? How Hot Foil Stamping Works in Printing & Packaging appeared first on Refine Packaging.

Chances are, if you glance around wherever you are right now, you’ll see a corrugated box or two. Maybe even more. 

I’m sitting at my office desk and I currently see six. And no, I’m not a hoarder. All of my office supplies and printing paper were shipped in these boxes and can be neatly stored away in them, too.

Even in my home, there’s almost always a few corrugated boxes hanging out in the corner of my room or closet. I’m forever trying to clear out stuff and these boxes are where I put items for donation. 

The particular box that’s near me now came from Trader Joe’s, which used to box up my groceries. Initially, Trader Joe’s received a shipment of frozen hash browns in this same box. As you can see, a single corrugated box can serve many purposes and is rarely single-use. 

You probably take corrugated boxes for granted, but they play an integral role in our business and home life. 

Corrugated boxes are ubiquitous in our homes and workplaces – whether you work in an office, a garage, a retail establishment, a restaurant, a fire station – or pretty much anywhere.  

Most products are shipped in corrugated boxes and many products remain in these boxes for convenient storage. Many retail packaging boxes serve multiple functions before they work their way to the recycling plant. 

It’s no wonder that the corrugated packaging industry is booming. And with an increasing ecommerce demand, coupled with consumers desiring more eco-friendly packaging options, it’s not looking to slow down anytime soon. Consider these stats:

• It’s estimated that the U.S. shipment volume of corrugated packaging will be around 443 billion square feet in 2023.
• The corrugated board packaging market was valued at over $262 billion in 2019, and is expected to reach nearly $400 billion by 2025.
• More than 95% of all goods consumed in North America are packaged and transported in corrugated packaging.

• There are over 1,100 corrugated manufacturing facilities in the U.S.

Corrugated boxes offer protection, are cost-effective, and can easily be customizable.  

What’s not to love?  

Deconstructing the Corrugated Box in Packaging

Most people refer to corrugated boxes as cardboard boxes, but they’re technically not the same.  

This can lead to some confusion with the terms. Cardboard is a heavy-duty paper stock, commonly used for folding cartons and other applications. 

You’ll find folding carton boxes lining grocery shelves are often made of cardboard. Think of a cereal or mac and cheese box. This type of box is not one you would expect to survive the shipping process. Toss one of these in the mail and they’ll likely arrive at their destination in tatters. 

A corrugated box, on the other hand, is all about strength.  

Corrugated boxes are made up of a liner and a medium. These sheets of paper are glued together. They’re typically made of three fiberboard layers, but can be even thicker. 

The outer layer is called the linerboard or simply the liner. Liners are the flat material usually found on the outside of the board, but sometimes inside like in the case of a double or triple wall. 

The medium is the wavy layer in the middle, which is called a flute. This inside player is what gives corrugated packaging boxes their strength and why they’re so commonly used for shipping and storage.  

What Process Goes into Making Corrugated Shipping Boxes?

I’ll go out on a limb and assume that we all know that corrugated boxes start their life as a tree. That aside, let’s take a closer look at how these boxes are manufactured. Here’s an abridged look at the corrugated box process: 

• The trees are cut down and bark stripped off.
• These logs are ground into wood chips.
• The woodchips are pulped using a chemical (sulfite and sulfate) or a mechanical (grinding) pulping process.
• A corrugated rolling machine makes the fluting.
• A corrugator machine presses and glues the layers of boards together.
• A die cutter cuts out features like flaps and scores creases.
• The board is cut and glued.
• And voila, you have a corrugated box. 

If you want to delve even deeper and see the corrugated box making process in action, YouTube has a surprising amount of interesting videos of what goes into making corrugated boxes.

Corrugated Boxes: It All Starts With Paper

There are two main types of paper used for corrugated boxes – kraft and test. 

Typically test paper is used for the inner liner and kraft paper for the outer liner of the box. 

Kraft paper is more expensive than test paper, but is higher quality.  

Kraft paper is made from softwood trees, such as Pine, Spruce, and Fir, and consists of 70-80% virgin chemical pulp fiber. It comes in several different versions, such as brown, white, mottled, fully bleached, and birch faced.  

Kraft paper also has a smoother finish, which makes for better printability. It’s also more water-resistant, which affords added protection to the goods inside. And because of its higher tear and burst resistance, it’s stronger than test paper. 

Test liners are usually made from hardwood trees that have short fibers, such as Oak, Sycamore, Birch or Chestnut, or recycled paper. Test paper is less expensive than kraft, but it’s less durable and harder to print on. That’s why test paper is often relegated to the inside of boxes, so it’s not as visible.  

Get to Know the Different Flute Grades for Your Corrugated Boxes

The flute (the wavy part sandwiched between the liner) is what sets corrugated boxes apart from their cardboard cousin. 

The flute size determines the thickness of the box walls and gives the box its stacking strength. Flutes are referred to by a letter that designates its size. They are measured by thickness and how many flutes per linear foot. Here are the most common flute sizes:

• A-Flute (33 flutes per linear foot) is the largest flute at 1/4” thick. Its thickness offers lots of protection and makes it a good option for fragile items.
• B-Flute (47 flutes per linear foot) is 1/8” thick. This is a lot thinner than A-flutes, but it’s deceptively strong.  It’s often used for counter displays or canned goods. This flute is popular for die-cut designs.
• C-Flute (39 flutes per linear foot) is 3/16” thick. This is the one you’re probably the most familiar with, since it’s the most popular option for shipping boxes.
• E-Flute (90 flutes per linear foot) is only 1/16” thick, so it’s pretty thin. It doesn’t offer the strength of the larger flutes but does have some advantages. It’s sometimes used instead of paperboard for folding carton boxes. It’s efficient to store and is good for printing.
• F-Flute (125 flutes per linear foot) is 1/32” thick and is among the thinnest of the flute grades. It has a very smooth surface, so printed graphics will look sharp. 

Picking the Right Wall Type for Custom Corrugated Boxes

Even if you know what flute size you want, you still have some important decisions to make. 

Corrugated packaging comes in all types of wall thicknesses. Sometimes you only need a little protection for your products, while other times you want something heavy-duty. Here are your wall type options: 

• Single-face: This is usually sold in rolls and is a single sheet of liner attached to one sheet of corrugated medium. It offers extra cushioning for delicate items. You might use this for added protection if you’re shipping something like wine glasses.
• Single-wall: This is one sheet of corrugated medium glued between two sheets of the liner. It’s the most common and is probably what springs to mind when you think of a corrugated cardboard box.
• Double-wall: This is more durable but less flexible.
• Triple-wall: This is the strongest, with three stacked corrugated sheets and four liner board facings. It’s used for industrial parts or sometimes for produce bins. 

Different Packaging Styles of Corrugated Boxes

Another important component when picking the appropriate corrugated packaging box for your products is finding the right fit. 

Corrugated boxes come in all shapes and sizes. You don’t want to have to cram your items, but you don’t want them swimming around either. 

When selecting a box size, keep in mind that the internal dimensions of a box are written as length x width x height (L x W x H).

Here are some of the most common box style options to choose from that come in varying sizes: 

• Regular Slotted Container (RSC):  This one is the most common. Think of your classic shipping box. With this box, all of the flaps are the same length, with the two outer length flaps meeting in the middle when the box is closed. You need tape to secure the flaps.

• Full Overlap Container (FOL): This type of box has added strength since both sets of outer flaps fully overlap, making it double-layered on the top and bottom of the box. 

• One Piece Folder (OPF): If you’ve ever ordered a book or other media materials, you’ve seen one of these boxes. They’re creased and slotted, then folded into a box. 

• Full Telescope Design (FTD): As the name suggests, this box has a separate top and bottom that fit over each other. The double walls give it extra strength.

Of course, these boxes need to be closed up somehow. Most commonly, corrugated boxes are closed up with packaging tape, tuck-in flaps, or strapping for heavy-duty loads. 

All of these choices can feel overwhelming, but there are many tools and services available to get you started on your quest for that perfect box. If you’re looking for a simple box, you can easily find a standard box template online.  

When you need something more complicated, with features like full 3D models or designing your die-cut templates, there are some sophisticated software options, such as ArtiosCAD, Impact, or Packmage. 

If you’re still unsure where to begin, request a free consultation with our packaging team for guidance about dielines, box styles, varnish and more that’s specific to your unique needs.

The (Many) Benefits of Corrugated Boxes for Shipping and Packaging

Boxes can be made out of all kinds of different materials, such as plastic, wood, metal, or paperboard, but there’s a reason corrugated boxes are such a popular option. 

Let’s take a closer look at some of the benefits of this type of box: 

Unrivaled Protection for Transportation and Shipping Safety

If your goods are being shipped in a corrugated box there’s a good chance they’ll arrive safely at their destination. 

Corrugated boxes can protect even the most fragile items, including glass and chemical liquids. The tear-resistant qualities of corrugated cardboard are hard to beat and they have the added advantage of guarding against moisture, so food items are kept fresh. 

The durability of corrugated boxes are one reason why so many companies use them as a staple of their shipping and fulfillment strategies.

Corrugated Boxes are Cost-Effective

The bottom line is important to all businesses. No one wants to waste money – especially on practical necessities.  

Corrugated boxes are relatively low cost to manufacture. Most of the time, custom boxes cost less than you might expect. 

Also, because they’re lightweight and can be easily stored, you can save money on storage and transportation costs.

Options for Custom Corrugated Boxes and Endless 

Corrugated box options are almost limitless. 

You can choose from all types of boards, weights, adhesives, coatings, treatments, flame resistance, static control – the list goes on. 

These packaging boxes can also be folded into all kinds of different shapes and box sizes. And we haven’t even touched on the exhaustive graphic design options corrugated boxes afford. 

There are all kinds of printing options so you can make your corrugated boxes unique to your brand.  

Corrugated Packaging Boxes are Environmentally-Friendly

Corrugated cardboard material looks like it fits the bill for consumers’ thirst to do right by the environment. Accenture recently surveyed 6,000 consumers in 11 countries and found the following:

• 83% of respondents thought it was important or extremely important for companies to design products that could be reused or recycled.
• 77% thought plastic was the least environmentally friendly type of packaging.
• But the good news for corrugated boxes, 55% thought paper products were the best option for the environment. 

Let’s look at some of the reasons, corrugated boxes get high marks for protecting the environment:

Corrugated boxes are easy to recycle

You have no excuses. In most places, you can just break down your boxes and put them in your curbside pick-up.  

• According to the EPA, in 2018, around 32.1 million tons of corrugated boxes were recycled out of 33.9 million tons of total paper and paperboard recycling.
• That year the recycling rate for corrugated boxes was 96.5 percent. 

Corrugated cardboard boxes are renewable

Corrugated packaging is made from a high percentage of recycled material (mostly in the 70-100% range). It can be manufactured from paper pulp that comes from fast-growing pine trees, or made from wood chips and other leftover materials.

Most corrugated box manufacturers get their paper from sustainable forests. No reputable paper company is going to be clear-cutting old-growth forests.  

Nope, quite the opposite.  

After all, it’s in the interest of paper companies to keep their supply going, so they’ll take actions like replacing harvested trees with seedlings. 

Corrugated shipping boxes are reusable

Corrugated boxes are easily collapsible, so you can break them down and store them in the garage until you need one for your next move or another future use.  

Corrugated packaging boxes save energy

Since corrugated boxes are mostly made using recycled materials, it takes less energy to produce them.  

Most are made without dyes and bleaches, so that’s one less step in the production cycle. They’re also relatively light so you can save on transportation costs.

Corrugated boxes are efficient  

A corrugated box offers a lot of protection so you don’t need it to be giant-sized or filled with excessive padding inside. 

Additionally, corrugated cardboard boxes are easy to stack or collapse when not in use – so you don’t need as much space to store them.

Drawbacks of Corrugated Boxes for Shipping and Packaging

Corrugated boxes can handle many of your packaging needs, but alas, as we all know – nothing’s perfect. As with anything, there are a few drawbacks: 

• A corrugated box, on its own, is not waterproof, so it’s not the best protection for the elements. If you leave a corrugated box in the rain it will eventually become a soggy mess.
• Both an unprinted or printed corrugated box does not have the strength of other materials, such as metal, so it might not be the best option for very heavy items.
• Sideways pressure may cause the corrugated cardboard to become deformed.
• It’s difficult for a corrugated box to maintain a pristine look. Because of its somewhat rough surface, even a box adorned with beautiful graphics may end up looking a little wrinkled and worn.  

But no matter your business, corrugated boxes will likely play a role in your custom packaging or supply chain needs. 

Testing Standards for Corrugated Packaging Boxes

Of course, if you’ve gone to the trouble of researching what flute grade and wall type you need – you understandably want some sort of assurance that the box will do what it’s supposed to do. And ultimately, that means protecting the products inside the box. 

Merchants, shippers, and consumers want to know they can count on the box to keep its contents safe. No one wants to receive a mangled box full of broken items at the end of a journey. 

Fortunately, corrugated boxes go through a rigorous testing process. 

There are several tests, with the two main tests used today being the Edge Crush Test (ECT) and the Bursting (Mullen) Test. 

These tests are important since most transportation companies, such as UPS, FedEx, airlines, and railways require shipping boxes to meet certain standards.

Here are four commons testing methods to consider for your corrugated cardboard boxes:

• The Edge Crush Test (ECT) measures the stacking strength of the box, which will let you know things like pallet shipping durability. ECT is a laboratory test method where the edge of the board is compressed between two plates. It’s measured in pounds per linear inch and is used to calculate the maximum compression force a box can withstand.
• The Bursting (Mullen) Test measures the force needed to rupture or puncture the corrugated cardboard. This test gives you an idea of how well a box will protect the goods inside during shipping.
• A Flat Crush Test measures the resistance of corrugated paperboard to flute crushing. This will help you determine how much pressure you can safely apply to your box during the printing process, whether you choose digital or offset printing.
• A Water Absorption Test (COBB) measures how much water corrugated fiberboard absorbs over a specified time under standardized conditions.  

Box Maker’s Certificate (BMC) 

These test results aren’t hidden away in a lab notebook somewhere.  

Nope, the results are often right in front of you. 

You’ve probably seen a circular stamp on the bottom of many corrugated boxes. 

Maybe you haven’t given it much thought, but that little stamp is chock full of information. It’s called a Box Makers’ Certificate (BMC) and has been widely used since around 1968, when the trucking and rail industry started relying on them.  

Today, this stamp is found on the bottom flaps of many corrugated boxes. 

Let’s take a look at what information you will find on a BMC:

• The name of the manufacturer and where the box was manufactured. This information is found in the outer ring of the circular stamp.
• Something along the lines of, “This Singlewall box meets all construction requirements of applicable freight classification.”
• The bursting test information (lbs. per sq. inch), or edge crush test information (lbs. per inch).
• The size limit (often given in inches).
• The gross weight the box can support. (Keep in mind this is the very upper limit.  It’s best to leave a little cushion.)

A Box Makers’ Certificate (BMC) doesn’t guarantee the box will protect the goods inside, since it doesn’t take into consideration things like moisture resistance, and of course you are responsible for any necessary padding inside.  

But, it’s a good starting point. At least you’ll know it’s not a good idea to cram a heavy barbell into a box only rated for ten pounds. 

In addition to the BMC, you may find other stamps on a corrugated box – depending on what is being shipped.  

Glassware, hazardous materials, and food often require additional stamps.  And many corrugated box manufacturers like to advertise their environmental credibility – so you might see stamps like “recyclable” or “sustainable forests” on the bottom of some boxes.

Don’t Settle for Dull Corrugated Boxes: Add Excitement to Your Packaging Design

What comes to many people’s minds when they hear the term corrugated box is a drab, brown rectangular-shaped box.  

Sure, this classic type of box serves a huge purpose, but corrugated boxes don’t have to be merely functional. They can also be used to enhance the unboxing experience and to pump up brand recognition. 

Don’t limit yourself to a boring shipping box; add some pizzazz.  

Why not take advantage of the advertising space? 

Go on and plaster your company name or logo on your custom boxes or seal them up with some custom packing tape. It’s easy enough to change up the look of your boxes, so you can even use different designs for holidays or the changing seasons.  

If you’re not sure where to start, here are some examples of companies that are making corrugated boxes their own with incredible product packaging design:

Fuego Box

It seems like there’s a subscription box for just about anything these days.  

If you’re into adding some spice to your meals, then Fuego Box may be just what you’re looking for. Fuego Box specializes in craft and small-batch hot sauce. Their product is all about the heat and their corrugated packaging box beautifully reflects their brand.

Hot sauces come in glass bottles so, in addition to looking good, their boxes need to be protective. You can order one bottle at a time, but if you’re feeling adventurous you can try eleven different bottles in their “Tame-to-Insane” challenge box. 

The eleven hot sauce bottles come in a large roll-end front tuck box with dust flaps. The front flaps lock into the main body for strength and security, while the side flaps keep out the dust.   

Pop open the box and the inside is filled with deep orange and red colors that just imbue a sense of heat. You know you’re in for something spicy when you lift open the box. All eleven bottles are carefully nestled in cardboard cutouts, which gives a higher-end look and offers added cushioning. 

FunFitFun

The outside of a corrugated cardboard box offers a large area to cram some serious branding. Some companies merely print their name or logo in a single color on the side of the box, but others go much bigger and bolder.  

Lifestyle brand, FunFitFun has made full use of the entire corrugated box – inside and out.  

Four times a year the company sends out ecommerce packaging filled with beauty, fitness wellness, and home items. They’ll never be accused of being drab. They cover the whole outside of their boxes with colorful graphics, which they change up to reflect the season. 

As the brand’s name suggests, the boxes are all about projecting a fun, healthy vibe.   

Custom Branded Packaging Tapes

Even if it’s not in your budget to plaster your corrugated boxes with your company logo and fancy graphics, don’t assume you can’t make your boxes unique. 

You don’t have to go all out. You can add a little flair to your shipping boxes at just about any price point. 

You’ve got to seal that box somehow. Custom packaging tape can serve a dual purpose – securely sealing your packages for transport and getting your brand noticed.   

Using affordable, branding packaging tape around your boxes can go a long way. The classic example is, of course, Amazon. Their corrugated shipping boxes are simple, yet there’s no mistaking where that box is from once you see that recognizable black tape with the blue lettering.   

But you don’t have to be a behemoth of a company to customize your boxes. Even small companies can order packaging tape to add interest to an otherwise ho-hum box. So, get creative, and design a tape that pops.  

Patagonia

Corrugated boxes, for the most part, are rectangularly shaped for ease of storage and transport, but you don’t have to limit yourself. You can make them in just about any shape you want.  

Outdoor clothing company Patagonia prides itself on its commitment to the environment and wanted its packaging to reflect that. 

These hexagonal-shaped boxes are both eye-catching and functional. The corrugate was left in its natural state with minimal printing, but the shape gives these boxes a distinct look. Not only does the box design look cool. Corrugated cardboard can also easily be stacked on store shelves for a neat appearance. 

Get Started with Customizable Corrugated Boxes

Corrugated paper has come a long way since it was first introduced in 1856 and used as a liner for top hats.  

It’s hard to believe that something that’s been around since the 19th century is still so widely used today. There have been some improvements made to the material during the intervening years, but there’s a reason corrugated boxes have had such staying power. 

No matter your business, corrugated boxes offer many options. 

They can protect your goods, they’re easy to transport and store, they’re affordable, they can pump up your brand recognition, and they’re one of the better packaging options out there in terms of the environment. These boxes will likely be storing and moving items from one place to another well into the next century. 

The post The Ultimate Guide to Corrugated Boxes: Corrugated Packaging 101 appeared first on Refine Packaging.

Varnish can make a huge difference to the appearance of your custom printed packaging.

When you need your packaging or printed material to stand out, consider using varnish to add a pop of depth to your colors or to add a subtle appearance that reflects your brand.

But what is varnish, exactly? What are the different types of varnish coating? What type of varnish will be the best to use?

We’re happy you asked.

The 4 Most Common Types of Varnish for Printing 

In the printing world, there are many different types of varnish, and each type has specific effects that you’ll want to better understand in order to choose the right style for your custom packaging. 

Let’s start with the 4 most common types of varnish coating used in printing and packaging:

• Gloss: Gloss is often applied over the full surface or in specific areas of your printed packaging. It creates and enhances the contrast between color while adding depth and detail to the color. Colors look like they “pop out” more to the naked eye. However, a high gloss finish under direct lighting can reflect a high degree of the lighting, which can make the text harder to read. 
• Matte: Matte gives your packaging design a more subtle, soft appearance. Because matte varnish is a non-reflective service, packaging with a lot of text, or text that needs to be read from a distance is better served by using a matte varnish as opposed to gloss. However, it’s worth noting that the effect appears much softer than with gloss finish. If you need your packaging to stand out and be noticed, gloss is still a better option.
• Strike-through Matte: Using this technique, matte varnish and gloss varnish are both applied to different areas of the printed piece. The matte varnish is applied to all of the areas except where a more impactful glossy effect is needed. In this way, the matte varnish strikes through the glossy effect and lets it shine while giving the rest of the packaging the more softer look. It’s a great way to create distinction between both types of the packaging. 
• Satin:  A combination of matte and gloss to create a “best of both worlds” varnish that is soft, yet allows for greater resistance against fingerprints, smudges and scuffs. It looks as if no varnish has been applied, so you can still enjoy a subtle effect, while giving your packaging enhanced protection during shipping. 

The Advantages of Varnish in Packaging and Print

Varnish adds (literally) a layer of quality to the box design or your printed product. 

Not only does it protect against scuffs, fingerprints and smudges, it also increases the perceived value of the product. Varnish can be applied via spot finishing or in different processes that span the whole sheet. 

Varnish is also flexible in terms of how it can be applied, which can create some unique and intense looks. 

For instance, with wet trapping, varnish is applied to wet ink during the printing process to truly ensure that the two meld together to create a distinctive style. With dry trapping, the ink is dried first and then the varnish is added by the press as well when the packaging passes through it a second time. 

The Disadvantages of Varnish in Packaging and Print 

If there’s one major disadvantage to varnish, it’s that it doesn’t offer the level of protection that other types of coatings like UV coating or aqueous coating (AQ) do. 

Varnish is also not exactly eco-friendly and needs to be applied carefully in order to prevent toxic byproducts from being released into the air. 

Consider how your varnish choice will impact your decisions related to soft touch coating or lamination, matte or gloss lamination and embossing or debossing.

A Variety of Effects and Styles for Varnish Coating

Varnish isn’t just divided by types, like satin and gloss, but also compromises different techniques as well.

For example, gloss UV coating is one of the most popular options, and is both protective and high-impact. If your custom boxes or packaging will be handled a lot, gloss UV coating adds a greater level of durability than other types of varnish. 

The UV in UV coating means that the liquid coating is applied and then cured with UV drying lamps. This makes the finished product very resistant to being rubbed or scratched. 

If you want to add an even greater level of sensory effect to your packaging, consider raised UV coating. This helps “volumize” the printed area or graphic by creating a raised area that not only sticks out more visually, but also in a tactile sense – you can feel the difference between the raised area and the non-raised area. Many DVD packages feature this type of printing where the characters or other noticeable area on the packaging is raised to invite touch. 

Another great way to add attention and focus to your packaging is through the use of a spot UV pattern. This means that only a certain area of the packaging, such as your logo, is glossy, and this is the part that reflects light and catches the eye.

Are Varnishes the Same as Laminates?

No, varnishes and laminates are not the same. 

That said, both laminates and varnishes are used to refer to the same process – where a protective layer is added to make a piece look more luxurious or softer. Both laminates and varnishes also protect your retail packaging from being damaged, but laminate protects more than varnish.

In many cases, especially if your product isn’t being handled a lot, varnish is a much more economical way to add a layer of basic protection to your product without investing in the higher cost of laminates. 

A Seemingly Endless Variety of Options and Techniques

With seemingly endless variations – from spot UV to high gloss coatings to a softer, more subtle matte that gives your product a more luxurious look, to velvet-like satin that adds a touch of softness and refinement – there’s a lot to consider. 

There’s a certain style that you want your packaging to project. Whether you want to convey the look of an elegant package that begs to be opened, or a high-impact, glossy, eye-catching piece that demands attention, every package has its audience and every audience has certain expectations in mind.

Adding to this, the fact that now, more than ever, packaging carries its own sense of brand loyalty-building through unboxings and streamings.

That means there’s no better time to entrust your packaging and printing to a leading custom packaging company that knows how to make your packaging deliver the best possible impression, no matter what you’re selling. 

From earthy, natural designs to sophisticated, classy looks, Refine Packaging has your needs covered with the very latest in proven printing techniques that truly bring your packaging to life. 

Make Jaw-Droppingly Good Packaging with Varnish

The best way to truly understand how the expert printers, packaging specialists and artists at Refine Packaging can help you is to give us a call or fill out our free, no obligation quote estimate form. Tell us more about your packaging, your product and your goals. We’ll take the time to carefully listen to your needs and formulate a plan of action to help you take the next steps with confidence.

In addition, even if you’re not sure of how you want your packaging to appear, or even if you don’t have a lot or design in mind, don’t worry! We have artists on staff that draw from a variety of styles and inspirations to create a look you’ll love. 

Using varnish as a way to finish your packaging is just one of the many processes we can employ to give your packaging an edge that helps make it more attractive among other products on the shelves. There are a variety of ways to add a touch of elegance, beauty, style and much more to the finished packaging to make it impactful and attention-getting.

Contact Refine Packaging today to learn more about the wide variety of options we can use to help make your product packaging look jaw-droppingly good and let our experts walk you through the process, as well as answer any questions you may have.

The post What is Varnish? How Varnish Is Used in Printing and Packaging appeared first on Refine Packaging.

Die cutting is used in the printing and packaging industry to refer to the cutting out of different shapes using machinery.

With die cut printing, it’s possible to specify exact measurements and have the machine cut them to exact dimensions every time.

As you might imagine, this precision is extremely useful for product packaging design, where you need to create a consistent and professional look each and every time. 

What is a Die? 

Die cuts start with a die, which is a metal object that has sharp areas for cutting.

A die resembles cookie cutters in that the shape that the metal object is designed will be the same shape that’s cut in the material. There are several kinds of dies. For example, steel-rule dies are very sharp, but are protected with plastic or foam for safety.

Steel-rule dies are made to cut thicker packaging materials, or to cut a stack of less-thick packaging all at once. There are also thinner metal dies, which aren’t as sharp and can’t cut very thick material. These types of dies are lighter in weight and easier to store, and also don’t have foam or plastic around them for safety. 

Manual and Digital Die Cutting Machines

Die cutting takes place with both manual and digital die cutting machines. Manual die cutting machines use a crank that is turned in order to cut the material. The metal die passes through the machine’s rollers and uses that pressure to help cut the shape out of the paper based on the shape of the die. Manual die cutting machines may also have motors that help to apply this pressure. 

Digital die cutting machines are generally controlled by software. They do not require steel dies because there’s a blade within the machine that cuts the shape. The software is used to select that shape and it can be created via computer, phone, tablet or even a specialized cartridge that the machine uses. 

Die Cut History: Why is it Called Die Cutting?

The origin of the phrase die cutting comes from the 1300s, from the middle English word ‘de’, believed to be from the Latin word “datum” for “given”, as well as put or placed. 

The root meaning of die cutting is to place or cast. Back in the 1300s, dies were primarily used to cast or stamp metal coins.

It wasn’t until the 1800s that the mass-production of items of a similar size and shape took off, and this old term “die” was used to specify that it was “created by machines”.

Cut refers to creating a custom shape, and die cutting means the casting and cutting of shapes.

The term die cutting was not commonly used until the 1800s, when it was meant as a method for creating more precise and accurate shoe sizes. Since shoes were made of leather, the soles had to be cut by hand, which was a tedious process that often led to errors and ill-fitting shoes.

When the die cutting machine was invented, this meant that shoes could now have standard sizes (something we often take for granted today).

The Role of a Dieline in the Custom Die Cut Process

Before you make a die cut on any printed material, you’ll want to first have an outline of what needs to be cut. This is where a dieline comes into the custom die cut process.

Dielines are part of die cut printing, and are used to outline the shape and packaging box size before any cutting happens.

With so many different shapes possible in the packaging world, if you can dream it, chances are a custom packaging manufacturer can make the material into any cuttable shape.

If you still need to make a dieline, read our guide about what a dieline is to learn more about how to make a dieline for your packaging and printing project. Remember, you’ll need a dieline before you can get to the finishing touches of your packaging like matte and gloss lamination, embossing and debossing or UV coating. 

Considerations for Different Types of Die Cutting Processes

There are different types of die cutting processes. The one used for your project will depend on your specific needs and your vision for your product. Some of the more popular methods include: 

• Blanking: Blanking takes flat material and slices it by clipping it from the outside edge, which makes it look even more flat. 
• Drawing: Drawing pulls material through the machine to a specific length. It is typically used for products that are thin and/or long. 
• Forming: Forming happens when the raw material is shaped on a curved surface. It is generally used together with your drawing to create cylindrical parts of your custom packaging. 
• Coining: With coining, circular holes are made in the material by adding pressurized force to them. This creates a very intricate look in packaging.
• Broaching: Multiple rows of “teeth” are used to cut material that the steel die cannot otherwise cut using the broaching method.

There are many other types of die cutting out there in both digital and offset printing, but this will give you an idea of the types most often used in packaging.

Beyond the types of die cutting, there are also different die cutting services depending on your needs. For instance, flatbed die cutting, also known as steel rule die cutting, uses a flatbed die cutting press and custom dies to create its custom shapes (dies). It’s ideal for thicker material, larger components of packaging or even short production runs. 

For higher volume production runs, there’s rotary die cutting which uses cylinder-shaped dies to convert flexible material into custom boxes or packaging. This is ideal for high-volume runs as well as designs that need exact accuracy.

There’s also digital die cutting, which doesn’t use dies at all. Instead, it uses lasers, blaces and tool bits to score, crease and cut the material. This type of die cutting is best used for applications that need fast lead times, but still require high levels of precision.

Can I Make My Own Metal Dies?

Although you technically can make your own metal dies by welding different pieces together, it is not recommended. In this case, it’s best to leave the die cutting, as well as the shaping and forming of dies, to the printing and packaging experts. 

If you have an unusual shape in mind for your custom packaging, it’s best to let us create the metal die for it, since this way we can be certain that it will work with our specialized machines. 

What Are Cutting Pads or Plates?

Cutting plates, also known as cutting pads, create a sort of “die cut sandwich” of all of the components and materials needed to make your packaging design happen. The “sandwich” is the type of packaging, the design and more so that the end result comes out looking exactly the way you envisioned. 

Think of it as a similar process as putting a cookie cutter through dough to create your ideal shape which you can then decorate. Die cutting is a similar process through the use of cutting pads or plates. Over time, these pads or plates need to be replaced because they can wear down. 

Using Die Cutting and More to Create Your Packaging

As you can see, die cutting is a very versatile way to accurately cut, shape and print your packaging so that the end results can be duplicated again and again without room for error. Not only is die cutting precise, but it also allows you a great deal of freedom with your retail packaging.

Still, we understand that not everyone is a packaging and printing expert. Fortunately, at Refine Packaging, we are. We’d be happy to answer any questions you may have about the die cutting process or how it will work with your product packaging vision.

If you have an idea in mind, but aren’t sure how to make it a reality with regard to your product packaging, don’t worry. We have a team of phenomenal artists and engineers that can turn your vision for your carton boxes, corrugated boxes or other branded packaging into a stunning, eye-catching reality. 

We invite you to contact us to request a free quote about our packaging and printing processes as well as our packaging design options to help determine the best way forward for your unique design. There has never been a better time to make your product come to life than with the knowledgeable experts at Refine Packaging. 

The post What is Die Cutting? What Die Cut Means in the Die Cut Process appeared first on Refine Packaging.

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.

Carton Boxes Defined

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: 

A Brief History of Carton Packaging Boxes

It’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 Packaging

If you’re looking for a practical, beautiful, environmentally-friendly box to hold your goods, then carton boxes are the way to go. 

The Practical Side of Carton Packaging Boxes

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. 

Folding Carton Boxes are Easily Customizable

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.

The Environmental Benefit of Paperboard Cartons

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 manufacturers are 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. 

Drawbacks of Carton Boxes for Packaging

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 Explained

After 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:

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:

• Reverse tuck end (RTE) boxes 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.
• Straight tuck end (STE) boxes 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 boxes are 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.
• Lock bottom boxes (sometimes called 1-2-3 bottom boxes) 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.
• Crash bottom boxes (sometimes called auto-lock bottom boxes) 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.  
• Top tuck boxes 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).
• Five-panel hanger tab boxes 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:

• Adding Inserts: 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 inserts can work with any folded carton type and are easily customizable to fit whatever random-shaped article you’d like to secure.
• Custom Cutouts: 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.
• Window Patching:  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: Thumb tabs are those little circular cutouts made in the main panel of the carton packaging to make the box easier to open.  

Practical Design Considerations for Carton Packaging Boxes

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.

Selecting Materials for Carton Boxes

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:

• Solid-Bleached Sulphate (SBS):  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. 

• Clay Coated News Back (CCNB): 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 cartons where recycled content is preferred, then CCNB may be the option for you. 

• Natural Kraft or Coated Unbleached Kraft (SUS or CUK): 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. 

Paperboard Thickness for Folding Cartons

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.  

Cost Considerations for Carton Boxes

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 Beautiful

Now for the fun stuff. Making your custom carton boxes beautiful and getting them noticed on a crowded shelf. 

Matte or Gloss Lamination: The Finishing Touch

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 finish doesn’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.

Branding: Printing Your Logo on Custom Carton Boxes

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:

• Your logo. You’ve no doubt put a lot of thought into that baby and it should have pride of place.
• Your colors. 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.
• Use materials that reflect your company’s values. If the environment is important to you – make sure your cartons reflect that. 
• Typography. Use a font that stays consistent with your brand identity. Don’t use a boring, staid font if you’re looking to project whimsy.
• Shapes. 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 Examples

Carton 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. 

Burlington Socks

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

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. 

Crabtree and Evelyn

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.

Beso Del Sol

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.

Lego

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 Boxes

There’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.

The post The Ultimate Guide to Carton Boxes: Carton Packaging 101 appeared first on Refine Packaging.

The days of throwing your products in an unmarked box and shipping them out to your customers are long gone.

Whether people choose to admit it or not, the truth is, first impressions matter. A lot. And you’ll never get a second chance to make a great first impression. 

Custom packaging is an incredible and cost-efficient way to not only impress your customers, but to leave a long lasting impact for your brand that leads to increased word of mouth, social sharing, brand loyalty and revenue.

Now, that’s the definition of custom packaging, but it really doesn’t describe why so many companies make the switch to go custom with their retail packaging. 

Custom packaging is so much more than printed cardboard or other material for your product. It’s a statement for your brand. A chance to build a physical connection with your customers. An opportunity to engage and delight people, while educating them about your company’s mission, values and product benefits.

Now let’s jump into the top 6 benefits that branded packaging can give your growing company.

1. Custom Packaging Is Your First Impression

Imagine it’s the first time you’re buying a product from a new company. 

The packaging arrives, and it’s like nothing you’ve ever seen before. It might be a custom box with the company logo, but it’s also somehow deeper than that. 

The packaging itself doesn’t feel like corrugated cardboard. It feels soft. Elegant. Refined. You can tell that it’s an upper tier product – before you even open the box. 

That’s the kind of first impression that brands want to make, and can make, when they have full control over the elements that go into their packaging.

2. Custom Packaging Is a Marketing Tool for Your Brand

If you want to present your product as high-end, all-natural, mysterious or cheerful, you can do all that and more with custom packaging. 

Through a combination of the right colors and materials, as well as the positioning of different elements and different printing processes, the pieces all come together perfectly. Like a fantastic puzzle where the real prize is inside, but half of the fun is opening the package itself.

Your brand has a story to tell. Every brand wants to be meaningful and to connect with its customers in a way that makes the brand relevant and interesting to them. 

Custom packaging boxes are part of your brand’s personality. And in many cases, it’s as much a part of the branding itself as the product within. 

3. Custom Packaging Boxes Are An Experience

If you’ve ever watched an unboxing video on Youtube or Facebook, you already know how much of a role custom packaging with your logo plays as part of the user experience. 

It’s not just one user opening a package in front of their fans, friends or family. It’s also a social experience. Especially for ecommerce packaging, where your package is often the only physical item your customer touches and feels throughout the purchasing process. 

The person familiar with the brand is also introducing that brand, often for the first time, to others who are watching. This becomes their first experience with the brand as well.

This social component plants the seed that if the people watching these unboxing videos want to experience something incredible, they should consider purchasing the item. 

Who knew that a package could carry those kinds of exciting feelings and that kind of sensation? Packaging design and printing teams understand this, and work with you to get it right, so that your consumers can enjoy such an experience, time and time again. 

4. Custom Packaging Sets Your Products Apart

For some companies, their custom packaging boxes are as much a part of them as their logo or name, and it would be unthinkable not to include it. 

Everyone has likely seen or heard of the small blue Tiffany’s boxes, with their tell-tale color. Anyone around knows at a glance that it’s a Tiffany’s box. They’ve put so much into their packaging, it’s unmistakable. 

If you can imagine, their box and its coloring have become so iconic, they’ve nearly transformed their packaging design itself into a piece of jewelry. That’s right, you can buy a “Tiffany blue” box necklace. 

But this is just one of many examples. For instance, if you wanted to project your brand’s emphasis on being environmentally-friendly, you might incorporate packaging items that are recyclable or biodegradable. 

Custom packaging boxes can make that happen through a combination of color, print material, printing process and of course the packaging design itself. 

5. Custom Packaging With Your Logo Is Memorable 

In a world of standard, bland boxes, custom packaging design stands out. 

Whether through the use of spot UV printing to make colors pop, or through specialized debossing or embossing that grabs attention, there are lots of options that can be included with your packaging to make it look unique and different from all the “same” styles of products on shelves.

It’s worth noting that if your product will be positioned under direct lighting, that certain types of printing can take advantage of this and create a very attractive and unique display that catches the eye and gets noticed. 

Even if your packaging won’t be positioned this way, there are still a number of printing processes that can make it stand out on store shelves and stay protected against things that could detract from its appearance like smudges or scuffs. 

6. Custom Packaging Is Worth The Investment For Small Businesses 

Of course, custom packaging boxes with your logo are often more expensive than your standard stock packaging, but it’s not just for the largest companies in the world. 

Small businesses stand to gain from all that custom packaging has to offer, too. After all, custom boxes cost less than you probably think. 

From stylish print options to unique packaging textures to shapes and designs that protect as well as create a great impression – there are several benefits to choosing custom packaging. 

Good packaging truly elevates your brand and your product to another level. That alone makes it worth the incremental investment. 

Is Custom Packaging Right for You? 

Branded packaging and custom boxes have a lot of benefits going for it that truly put your product in a class all its own. But it’s worth noting that there are other points to keep in mind, such as the number of custom package prints you want and the cost associated with designing the different plates (for use in the printing process) and so on. 

The printing world, for all of the magic and wonder it can create, is still a complex one. And whether this is your first time getting your product packaging printed, or you’re looking for alternatives, we want to help.

As one of America’s largest wholesale custom packaging vendors, our team at Refine Packaging makes it our business to get to know your business. 

Who are your customers? What do they want from your product? What would you like your product to convey when they open the package? What do you want them to experience? All of these things are intertwined and matter just as much as the product itself. 

With that being said, it’s easy to feel overwhelmed at the sheer number of printing options out there for your custom packaging needs. What is a dieline? What’s RGB and CMYK? What is the Pantone Matching System (PMS)? What’s aqueous coating? We want to help you understand the many different options available to you while still staying within your budget. 

Contact us today for a free estimate on your custom packaging solutions and supplies. Learn more about our prices, our process and how we can help you. We’ll take the time to get to know your unique needs, your product needs, and how we can help. 

From artists on-staff that are ready to help bring your artistic vision to life, to printing professionals that are ready to make your box design truly shine, we have the knowledge, experience and expertise to ensure that your custom packaging looks flawless from start to finish.

The post What is Custom Packaging? The Top 6 Benefits of Branded Packaging appeared first on Refine Packaging.

Why Is It Called a UV Coating?

The UV coating itself is applied in a liquid form. Then, as the name implies, the packaging is exposed to UV (ultraviolet) light, which then causes it to instantly dry and bond to the material it’s coating. This coating can be used over the entire area – a process known as “flooding” or it can be applied to certain areas, which is known as spot UV coating.  

In addition, there are different levels of “sheen” available for UV coating. High gloss UV coating is often the most popular choice, but if you need a more subdued look, that’s also possible with UV coating. 

Compared with other coatings, UV coating is more durable than aqueous coating, although not quite as much as direct plastic laminate. UV coating dries relatively slick, so if for any reason you’d need to write on the surface, print over it, glue it or apply certain kinds of labels to it, they likely won’t stick unless those areas are excluded before starting the UV coating process during printing. 

Benefits of UV Coating in Printing

UV coating offers a number of benefits over other types of coating, including: 

• High-gloss, high-shine finish: Deep, dark colors appear richer and can almost look wet with the right type of finish on UV coating. This vivid look is what makes UV coating a popular choice for people who want their packaging design to really stand out. Learn more about the differences between CMYK vs RGB and Pantone colors as you explore if UV coating makes sense for your needs.
• High-clarity: Logos and photographs are ideally suited for UV coating because of its ability to make them richer and more vivid. 
• Resistant to scuffs: If your packaging will be handled a lot, you’ll be glad to know that UV coating offers an added layer of protection, as it’s slightly thicker. It also resists accidental smudging and marking, while still looking professional and polished.
• Dries immediately: The moment the coating hits the UV light, it dries instantly, so there’s no waiting. Less waiting means less production time, which means you can ship out and deliver your product into the hands of eager consumers faster. This is especially true for ecommerce packaging, since your packaging and product are often your only physical touchpoint with your customers.
• Environmentally friendly: UV coated packaging material can be recycled with your other materials, so it’s not hazardous to the environment. 

Drawbacks of UV Coating in Printing

There are a few cases where UV coating is not a good fit for your printed project. For example: 

• If you’re using metallic ink: The metallic ink can mar the surface of the packaging. 
• If you have weighted paper below 100#: Thinner paper may curl when the liquid UV coating is applied, even though it dries immediately. 
• If the piece has foil stamping: This is a mixed bag in the printing world. It’s possible to get decent results because there are foil stamping options for UV coating, however, success depends on a variety of factors that need to come together precisely in order to achieve the kinds of results you want. 
• If the piece needs to be written on extensively: As noted, the high gloss and sheen provides for a slick surface that causes most inks to simply rub off. 

Lamination, such as matte or gloss, may be perfect for your specific needs. With that said, UV coating is often one of the most cost effective and affordable options to add a layer of durability and protection to the finished box design or other printed piece. Plus, it won’t weigh down the finished result the way that other types of coatings or coverings can. 

Add a Little Something Extra to Your UV Coated Packaging

Different types of coating make your product packaging design stand out in different ways. It’s important to know before you begin, the kind of results you want to achieve. Along with UV coating, there are certain additional options that you can include to create a remarkably different effect.

For example, spot UV coating is great when used with logos to add a layer of dimension. It naturally draws the user’s eye and their attention, so you can highlight important areas on your packaging that you want your customers to see and notice. 

Another option is soft touch coating. This adds a velvet-like, soft matte look to the piece, which gives it a touch of elegance and sophistication. 

We invite you to read more about both spot UV coating and soft touch coating in detail to learn more about how these similar methods of digital or offset printing can help add a touch of refinement to your product packaging. 

Of course, seeing (and touching) is believing, so if you have questions about how the finished product looks and feels, we invite you to request samples so that you can see the differences in all of the coating options to decide which one is best for your specific needs. 

Have Questions About UV Coating for Your Printed Packaging?

We understand that it’s one thing to request samples and look over the different options, versus actually speaking to a packaging and printing expert to get your questions answered and get more information.

If you have questions about UV coating for your printing packaging, or other types of packaging or printing questions, we’d love to speak with you! We promise to explain things thoroughly, without the use of printing jargon and technical explanations so that you ultimately benefit from our knowledge, experience and expertise in a way that positions your packaging in the best way possible. 

UV coating is just one of the many types of coatings and printing options available for your product packaging. Contact us today to learn more about your options and let’s work together to bring your packaging vision to life in a way that attracts your perfect customer and builds brand awareness and loyalty.  

The post What is UV Coating? Make Your Colors Pop With UV Coating for Printing appeared first on Refine Packaging.

Color can make or break a product’s packaging design.

Think about the red and yellow arches that are printed on every McDonalds happy meal. They’re iconic. And part of what brings those colors to life are the RGB and CMYK color models that are used during the printing process for each and every one of those happy meal custom boxes.

So what is CMYK color in printing? What does CMYK stand for? And what does the RGB color model have to do with it all?

RGB and CMYK are both color modes used in the printing process. But when you’ll use each one depends on a variety of choices that you’ll need to decide before your packaging box design is printed. Let’s jump right in.

Offset printing machines combine varying levels of these 4 colors using physical ink in the CMYK process called “subtractive mixing“. When all of the colors are mixed together, the result is pure black. 

When Should You Use the CMYK Color Model in Printing?

CMYK is best used for printed material. It’s more accurate than RGB, which we’ll describe below, and allows for subtle differences in shade and tone (subtleties that digital devices cannot “see” but our eyes can still perceive). 

If you use CMYK printing, you’ll have more accurate results compared to the RGB color model. Learn about the Pantone Color Matching System (PMS) which was created to help standardize color variations when using CMYK.

What File Formats are Best for CMYK?

PDF is the best file format for CMYK printing because of its wide compatibility. For logotypes and other product design elements, Adobe Illustrator’s AI format is often used, as is a similar standard from other vector software of EPS. We work with all of these types of formats, so feel free to use whichever one you prefer and you can be confident that we’ll be able to work with it. 

In the RGB color model, all colors start out as black. As more red, green or blue are added and at different intensity levels, the colors change accordingly. At their highest levels of intensity, the light from the device is mixed completely at the same level for each color, creating pure white. 

From here, the designers can vary the saturation of color, the shade of the color and its vibrance level in order to get the exact color they want, based on how the light and darkness are shown on the screen of the device they’re designing for. 

When Should You Use The RGB Model in Printing? 

The RGB color model is typically only used for designs that will be viewed solely on screen. If you’ll be using your design both on screen and in print (such as on your website and your product packaging), it’s normal to have a version as RGB and one as CMYK, which we’ll outline in more detail below.

The most common uses for RGB are things like graphics, buttons, icons and web-based logos. 

What File Formats are Best for RGB?

JPG is normally the standard for RGB files, normally because it strikes a good balance between quality and file size. If everyone will be working with Adobe Photoshop, PSD is a commonly used format. Use PNG as the format if you want parts of the image to be transparent, or if the image is made up of a few colors. Icons, buttons and other graphics are often saved as PNG files.

If you’re going to be using animation, GIF is the ideal format to use. You’ll want to avoid BMP, TIFF, EPS and PDF as there are often compatibility issues with these older formats, and the file sizes are unnecessarily large and cumbersome to work with. 

What’s the Difference Between RGB and CMYK Printing?

The difference between these formats is that the colors will render differently depending on whether they’re viewed on a screen (RGB) or on a print device (CMYK). The rendering of the different modes depends on how the colors “mix”. 

RGB printing has a larger range of possible colors, while CMYK has the ability to make the colors more vivid. That’s why, if you transfer a CMYK image, it will show less of a range of colors and may look slightly different on screen than in print.

Conversely if you tried to print an RGB image, it would look muted and dull in terms of its coloration. It is possible, however, to convert RGB to CMYK using software, so if you have an RGB or CMYK image and you need it changed to the different mode, it’s no problem to do this in Adobe Photoshop or Adobe Illustrator.  

We can convert your logo or other file formats before printing if you need this done, to ensure excellent results with your printed design. Keep in mind that there is no 1:1 correlation between the colors, but they can come very close to matching each other. 

Keep reading: Learn about embossing vs debossing, spot uv for printing, aqueous coating, soft touch coating and lamination as you explore your packaging and printing needs.

Still Have Questions About Working with CMYK or RGB Color Modes? 

At Refine Packaging, we understand that you may still have questions about the different color modes than what’s answered here. We’re happy to convert your files so that the end result will look flawless in print. 

We can also advise you on the best type of retail packaging to fulfill your product development vision and ensure that your product is treated with the best possible care and precision in printing to have a package that equally matches your brand’s personality and style. 

And even if you’re not sure exactly what sort of design you want, we have a team of artists from a variety of backgrounds who are ready to step in and help. We’ll take the time to get to know your unique vision for your product, as well as who your target audience is, so that we can create a congruent match between product and customer. 

We then work to better understand your budget so that we can make cost-effective suggestions that maximize your product’s packaging design without breaking the bank. 

Finally, when all is said and done with the design, we can suggest packaging options that fit the theme, box size or style of the look you want to convey. Whether it’s classy and sophisticated, or you want to draw attention to your logo or lettering, there are numerous print styles and processes that can help you achieve all of this and more.

Contact us today for a free quote on your product packaging design and printing needs and let’s work together to create a professional look that perfectly matches your brand and vision!

The post What Are The RGB & CMYK Color Models In Printing? Learn Color Modes. appeared first on Refine Packaging.

In the printing world, the phrase “soft touch” refers to any type of finishing that adds a softer feel to a printed material. 

While many packaging customizations are focused around visual appeal, soft touch coating and soft touch laminate are gifts for your customer’s tactile senses. 

But what’s the difference between soft touch coating and soft touch lamination?

Soft touch coating and soft touch lamination are both finishing methods that change the feel of your printed material, the primary differences lie in their application process. 

Let’s first cover what soft touch finish feels like, then dive deeper into which option makes the most sense for your unique printing project.

What Soft Touch Feels Like

Soft touch is often called a velvet finish, because this type of finish is frequently used on retail packaging that needs a softer and more subdued sense of refinement and quality.

Soft touch printed materials have a sort of velvety softness and texture, often described as suede-like or soft leather-like. With that said, describing the feel of soft touch printed items is like asking someone to describe the color red – you’ll get all kinds of answers, from a deep crimson to an almost pink, and everything in between.

Materials with soft touch printing are the same way. Most pieces feel slick and shiny, but soft touch finished pieces are subtle and don’t have much sheen, making them a great option to create a look of luxury and elegance. 

Soft Touch Finishes: The Process for Soft Touch Coating vs Soft Touch Laminate

Adding a soft touch finish to your product packaging is done by either applying a coating or laminate film. 

• Soft touch coating is applied as liquid during the inline process once the printing has been completed. As the coating dries, the piece is left with its velvety soft touch texture.
• With soft touch laminate, a uniquely textured matte film is bonded to the top of the printed piece. This makes the surface have a softer feel and low luster. 

Both methods will give you that soft feel, but it’s worth noting that soft touch coating that’s applied with liquid is usually less expensive, compared to laminate. 

If your custom packaging needs to be more durable, however, the laminate option frequently holds up better in terms of improved strength.

If you prefer the feel of soft touch coating, there are different types of varnish, such as aqueous coating that’s commonly used in offset printing, that can provide increased sturdiness.

The Benefits of Soft Touch Coating and Soft Touch Lamination

With its combination of a sophisticated matte effect, together with a luxurious velvet feel, soft touch coating offers a variety of benefits in terms of durability and longevity. 

Printing with soft touch coating makes for an excellent customer experience which in turn reflects well on the brand. It’s ideally positioned as the king of unboxing experiences because customers love how soft and unique it is. It’s also resistant to being scuffed during the finishing process. That makes it perfect for use in printed materials like solid colored matte boxes, regardless of using pantone (PMS) colors or CMYK variations. 

If you want your product to enjoy improved durability, but you want a more subdued look and feel than the regular glare and shine of most packaging, soft touch is a great option. 

However, keep in mind that if you’re interested in soft touch laminate to add an extra protective layer against fingerprints, yellowing and smudges, that this process is more expensive than simply using soft touch coating.

Other less expensive options you may want to consider, which can still give your product a distinctive look and feel include embossing or debossing, as well as spot UV printing.

What Types of Printed Products Use Soft Touch Lamination or Soft Touch Coating? 

Nearly any printed material that needs a soft, elegant and subdued effect will benefit from soft touch lamination or soft touch coating. Many luxury products that are made for women, such as cosmetic packaging, feature soft touch. But this is by no means the only industry that benefits from soft touch finishes. 

Luxury products of all sizes and shapes that use a soft touch in their packaging appear that much more sophisticated and refined. If you want to move away from the bright, bold glares and reflective sheens of more eye-catching packaging or box design and toward something a bit more elegant and classy, soft touch finishing could be the perfect option for your needs. 

Soft touch finishes are often used in the jewelry and high-end fashion industry, as well as with more expensive audio and technology components. Although this type of matte doesn’t have the reflective brightness that it’s more high UV cousins carry, it nevertheless attracts attention in its own unique way. 

Soft Touch is More than Just a Hot Design Trend 

Because of the popularity of social media shareability and unboxing videos, soft touch printed materials have understandably surged in popularity. What’s unique about the printing and packaging design industry is that even within the work we do here at Refine Packaging, there are numerous smaller “sub industries” that we have to understand down to the finest details in order to create packaging that fits their customer persona. 

With that in mind, our customers understandably want to do everything they can to create an eye-catching look, and soft touch finishes are one of the best ways to do that on multiple levels. Soft touch works alongside other printing options and is perfectly at home among different processes. 

Imagine a printed package that used a soft touch finish together with a spot UV print to highlight certain areas, or with an embossed effect and you can see how soft touch finish not only coexists happily with other types of printing methods, but the results can look nothing short of incredible. 

Although we’ve talked about a soft touch finish having a more muted look, this doesn’t mean that it fades or washes out your colors. Vibrant, high contrast colors are still just as bold and vivid as they ever were (if not more so), and the soft touch brings out the tactile, as well as heightening the visual sense of these packages. Imagine running your hand along an elegant suede coated customized box – it feels like velvet and echoes refinement and style, all in one. 

Interested in Learning More About Soft Touch Finishes? 

It’s one thing to talk about the difference between soft touch laminate and soft touch coating, and another thing to experience it first-hand for yourself. At Refine Packaging, we’ve been helping users from a variety of backgrounds conceptualize, create and complete their vision with a variety of beautifully and artfully printed packaging that perfectly reflects their brand and what they want it to convey. 

We take every aspect of your product packaging and work hard to refine it into something that is the perfect extension of your brand, not just a container for your product. To that end, whether you need help creating a design or you want something that will stand up to the rigors of the shipping process, or something elegant and soft, we’ve got your needs covered every step of the way. 

Contact us today to request a free quote or learn more about our wide range of printing and packaging design services. Browse our portfolio and let’s talk more about bringing your idea to life with stunning packaging that protects and promotes your product in a way that nothing else can. 

The post Soft Touch Coating vs Soft Touch Lamination: Use The Best Printing Finish appeared first on Refine Packaging.

When it comes to packaging and printing, you’ve probably come across the phrases Spot UV Coating or Spot UV Printing. 

But what is spot UV, exactly? Should spot UV coating be considered for your printing? How can you print spot UV on packaging?

Let’s take a closer look at what spot UV is and why you may want to consider this as part of your printed packaging to make your products shine.

Spot UV and spot gloss are methods used in print finishing that involve putting a high-gloss UV coating on a certain area of the final printed product. 

A primary reason for using spot UV is to make the CMYK or PMS colors of your printed material shine and appear more vibrant, so you can draw more attention to that targeted area.

If spot UV finish is applied to the company logo of your custom boxes or other packaging, then your logo will have a nice, glossy sheen. This helps your brand to stand out with a more unique packaging design with an eye-catching appeal. 

This printing technique involves using ultraviolet (UV) light to help “cure” the coating that is applied to protect the packaging (gloss or varnish). Not only does this help seal in the vividness of the color, but it also adds an additional layer of protection to the finished product. UV coatings can vary from a glossy look to a highly reflective shine. As the name implies, with spot UV coating, this protective coating is only added to certain areas. 

The moment this affected area is exposed to UV light, the coating dries instantly, which lets designers get creative (and precise) with the covered area. Spot UV is a great way to lock in the shine and add a protective touch over the areas of your packaging that are most important to you. 

What is Blind Spot UV? 

Blind spot UV is often used for darker-colored packaging, however, the spot UV process for blind spot UV is similar to that of spot UV finish. The printing technique is the same, but the design steps are slightly different, providing a different creative effect to the finished piece.

How Blind Spot UV is Different from Spot UV

Blind spot UV differs from Spot UV in that it’s a different style of design approach. The method of applying a high-gloss UV coating to a specific area of the print is the same. 

With spot UV, a “mask” file is created in the design that shows where the press should add the UV coating. Most of the time, this mask perfectly matches the size and style of the logo or the area where you want to create emphasis. 

Since the spot UV gloss is clear, it can be applied to more than just the logo. For example, spot UV finish can be applied across the entire packaging even if it has lettering on it, without affecting the readability. With blind spot UV, you can see the results better on a darker background. 

If spot UV coating is used on a matte finished or uncoated style of packaging, the color under it will appear more vivid in contrast than it truly is. Black colors will look darker, as will similar colors. 

Of course, that isn’t to say that this type of coating technique won’t work for white or brightly colored packaging – it will, but the effect is different. Rather than being contrasting between darkness and light, the gloss effect will be more subdued with spot UV printing. 

Benefits of Using Spot UV Printing for your Packaging

There are several great reasons to consider adding a touch of spot UV in your custom printed packaging. Most notably, some of spot UV’s greatest benefits include: 

• Incredible Shine: Spot UV finish offers the eye-catching and attractive appeal of a lustrous shine under direct or even more subdued lighting. It’s aesthetically beautiful and adds a touch of sophistication to any package.
• High Clarity and Readability: Although the spot UV printing does add a glossy look to your retail packaging, each word is still clearly legible and easy to read. This means you get the best of both worlds when it comes to having a unique look that gets noticed, with easy legibility at a distance.
• Protective Against Smudges: Packaging gets handled a lot. And although it’s no one’s fault, sometimes your design can be marred by smudges and fingerprints. Spot UV can help prevent that by offering a protective layer between the packaging and constant handling.
• Environmentally Friendly and Safe: Because spot UV coating is so precise, the coating itself stays exactly where it’s placed and doesn’t escape into the air, making it a great option if you’re looking for an environmentally friendly packaging option. 

Are There Areas Where I Shouldn’t Use Spot UV Printing? 

Spot UV printing is extremely versatile and can be used in a wide range of packaging printing and other materials. 

Possibly the only option where it’s not recommended is on very thin packaging. Other than this, there are virtually no restrictions to using spot UV finish on your packaging box design.

Using Spot UV Printing on Matte Finish

Packaging design with a matte finish serves as a great option for a spot UV finish. 

Thanks to the more subdued matte background, the high gloss shine of the spot UV coating provides an excellent contract. 

This same idea can be carried over to spot UV coating as well, creating a beautiful, elegant look that adds a more refined style to your finished packaging. If you want your packaging to look premium without the higher price tag associated with high gloss printing, spot UV coating is an option you’ll definitely want to consider. 

Using Spot UV Printing on Matte Lamination

Spot UV with matte lamination adds softness and shine to the finished printed material. Because dark colors appear darker, it’s a great way to make your logo stand out and get attention when it’s added with spot UV printing. 

While you determine whether to use spot UV, don’t forget to consider matte or gloss lamination, what types of aqueous coating to use, and if embossing or debossing makes sense for your specific printing needs. 

What About Raised Spot UV Printing? 

People often request raised spot UV printing, but in the printing word, this term doesn’t exist. Instead, the phrase that’s usually meant is raised ink printing. 

Raised ink printing is a technique where a transparent coating is placed over certain areas of text, your logo or other parts of your design. This adds texture and style to the packaging that can be felt at a touch. 

In order to give a package design the raised ink look, powder is added to certain areas of the design or text. It is then heated which causes a chemical reaction to occur and the ink to look “raised” by transforming into a hardened gel that gives it depth and contour. 

What If I Still Have Questions?

If you have questions about how to print spot UV on your packaging, that’s understandable. After all, you want your packaging to look as professional and beautiful as possible. And Spot UV, blind spot UV, and raised ink printing are all fairly technical printing methods. 

At Refine Packaging, we understand that every customer has unique specifications and ideas in mind to create the perfect look. We invite you to contact us to learn more about spot UV coating and other techniques that can be used to help create the ideal look for your packaging. 

No matter what you have to sell, Refine Packaging can bring your vision to life. With several creative ideas and packaging that sets your product apart, we have the knowledge, experience and expertise to perfectly reflect your brand. 

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