Custom Solutions
Packaging Engineered Around Your Product
Off-the-shelf boxes work for most applications — but when your product has unique dimensions, fragility requirements, or branding goals, you need packaging designed from the ground up. Our custom solutions team turns your requirements into production-ready packaging.
Custom Packaging Services
Custom Die-Cut Boxes
Precision die-cut boxes manufactured to your exact product shape and opening requirements. We design RSC, tuck-top mailers, auto-bottom trays, display boxes, and any specialty configuration you need. Our structural engineers optimize flute direction, score lines, and tab geometry for maximum strength with minimum material.
- CAD design included with every order
- Steel-rule and rotary die options
- Minimum order: 250-500 units depending on complexity
- Lead time: 7-12 business days for first run
Specialty Fragile Packaging
Engineered packaging systems for items that demand the highest level of protection — glass, ceramics, electronics, medical devices, artwork, and precision instruments. We combine custom foam inserts, suspension packaging, double-boxing, and shock-indicator technology to guarantee safe arrival.
- Drop-test validated designs (ISTA 2A, 3A protocols)
- Custom foam: PE, PU, cross-linked PE, anti-static
- Suspension systems for extreme fragility
- Climate-barrier options for temperature-sensitive products
Custom Inserts & Padding
Interior packaging components designed to hold your product securely and prevent movement during transit. From simple corrugated partitions to CNC-routed foam cradles with exact product contours, we engineer inserts that eliminate damage and reduce void-fill waste.
- Corrugated dividers, trays, and pads
- Die-cut and CNC-routed foam in any density
- Molded pulp inserts (eco-friendly foam alternative)
- Kitting and pre-assembly available
Modified Gaylord Boxes
Standard gaylords adapted to your specific workflow. We modify height, add access doors, install hand-holes, reinforce bottoms, add liners, and create multi-compartment interiors. If you need a bulk container that does not exist off the shelf, we build it.
- Height reduction or extension from standard 36"
- Drop-front and side-access door modifications
- Reinforced bottoms for heavy or sharp-edged products
- Integrated poly liners for liquids and powders
Rebranded Used Boxes
Take advantage of the cost savings and sustainability of used boxes without sacrificing brand presence. We apply custom-printed kraft overwrap, large-format labels, or full-coverage stickers to used boxes, giving them a branded appearance at a fraction of the cost of custom-printed new boxes.
- Full-coverage kraft overwrap with flexo printing
- Large-format adhesive labels (up to 24" x 36")
- Stencil printing directly on used box surface
- Minimum order: 100 units for overwrap, 50 for labels
Custom Sizing from Used Boxes
Need a size we do not carry? We can cut down larger used boxes to create the exact dimension you need. Our box-scoring equipment cleanly re-scores and trims used boxes to custom heights and widths, preserving structural integrity while eliminating the cost and lead time of manufacturing new.
- Height reduction is the most common modification
- Clean scoring maintains fold accuracy
- No minimum order for cut-down services
- Same-day turnaround for standard modifications
Our 6-Step Design Process
From initial conversation to final delivery, every custom project follows our proven six-step process. Each step has defined deliverables so you always know what to expect and when.
Discovery & Consultation
We start with a conversation about your product, your logistics, and your goals. What are you packing? How heavy is it? How far does it travel? What impression do you want to create? We review your current packaging, identify pain points, and define project requirements.
Deliverables: Requirements document, preliminary material recommendations, rough budget range
Structural Design
Our structural engineers create a CAD model of the packaging, selecting optimal board grade, flute profile, and construction style. We use TOPS software to model stacking performance and transit hazards. Multiple design options are presented with trade-off analysis.
Deliverables: CAD drawings, dieline files, material specifications, cost estimate per design option
Graphic Design (if applicable)
For printed packaging, our graphic design team creates or adapts your artwork to the structural dieline. We handle color management, dot gain compensation, bleed setup, and prepress preparation. Full-color mockups are provided for approval before prototyping.
Deliverables: Print-ready artwork files, digital mockup renderings, color specifications
Prototyping & Testing
Physical prototypes are produced on our sample-making table — typically within 2-3 business days. You receive actual-size samples to test fit, evaluate appearance, and run shipping trials. ISTA compression and drop testing is available for validated designs. Revisions are included.
Deliverables: 3-5 physical prototype samples, test reports (if ISTA testing requested)
Tooling & Production
Once the prototype is approved, we build production tooling (dies, printing plates) and run a pilot batch for final quality verification. Full production follows with in-line quality checks. We maintain SPC (Statistical Process Control) on critical dimensions.
Deliverables: Pilot batch for approval, production run, quality inspection reports
Delivery, Reorder & Optimization
We deliver to your facility, warehouse, or fulfillment center. All tooling is stored for fast reorders. We proactively monitor your usage patterns, suggest material optimizations as costs change, and adapt designs as your product line evolves.
Deliverables: Scheduled delivery, stored tooling, reorder pricing schedule, ongoing support
Material Options
We work with a full range of corrugated and specialty materials. The right choice depends on your product weight, fragility, branding needs, and sustainability goals.
| Material | ECT Range | Printability | Sustainability | Best For |
|---|---|---|---|---|
| Virgin Kraft (Single Wall) | 32-51 ECT | Good (1-2 color flexo) | Recyclable, FSC available | Industrial, B2B, shipping |
| Virgin Kraft (Double Wall) | 48-71 ECT | Good (1-2 color flexo) | Recyclable, FSC available | Heavy items, fragile goods |
| White Top Kraft | 32-51 ECT | Excellent (full-color) | Recyclable | Retail, branded, premium e-commerce |
| Litho-Laminated | 32-48 ECT | Superior (photographic) | Recyclable (check laminate) | Shelf-ready, luxury, subscription |
| Recycled Test Liner | 32-44 ECT | Fair (1-2 color) | Excellent (recycled content) | Cost-sensitive, eco-priority |
| Wax-Coated / Curtain-Coated | 32-48 ECT | Limited | Recyclable (check coating) | Moisture, cold chain, produce |
| Triple Wall | 80-120 ECT | Fair (large format flexo) | Recyclable | Crate replacement, heavy industrial |
| Corrugated + Foam Hybrid | Varies | Per corrugated specs | Mixed (foam is not recyclable) | Electronics, medical devices, precision instruments |
Printing & Branding Capabilities
Flexographic Printing
Direct printing on corrugated using rubber or photopolymer plates. 1-4 PMS colors at 85-133 lpi resolution. Cost-effective for moderate to large runs. Plates are stored for reorders, eliminating setup costs on subsequent orders.
MOQ: 500 units | Lead: 7-10 days | Setup: $250-$700/color
Litho-Laminate Printing
Full CMYK + spot color offset printing on a smooth paper sheet, laminated to the corrugated substrate. Achieves photographic quality at 175+ lpi. Supports gloss, matte, soft-touch, and spot UV finishes for premium brand impact.
MOQ: 1,000 units | Lead: 14-21 days | Setup: $1,500-$3,000
Digital Printing
High-quality digital printing directly on corrugated or on a laminate sheet. No plates required — ideal for short runs, versioning, and variable data printing. Produces near-litho quality at lower quantities without setup costs.
MOQ: 50 units | Lead: 5-7 days | Setup: $0 (no plates)
Stencil & Label Overprint
For rebranded used boxes or cost-effective identification, we offer stencil printing (1 color, large format) and pressure-sensitive label application (up to 24x36 inches). Fastest turnaround and lowest cost for basic branding.
MOQ: 50 units | Lead: 1-3 days | Setup: $50-$200
Custom Packaging Case Studies
Real examples of how our custom solutions team solved unique packaging challenges across different industries.
Consumer Electronics
Challenge
A Bellevue-based electronics brand was experiencing a 4.2% damage rate on their flagship smart speaker during e-commerce shipping. The product weighed 3.8 lbs and had a premium matte finish susceptible to scuffing.
Solution
We designed a custom die-cut corrugated cradle with integrated foam bumpers at the four corner points. The cradle locks the product in suspension inside a custom-printed mailer box, maintaining a 2-inch air gap on all sides. The outer box uses 44 ECT white top kraft with full-color litho-laminate.
Results
Damage rate dropped to 0.3%, packaging cost decreased 18% vs. the previous foam-and-box system, and the branded unboxing experience generated significant social media attention. Customer satisfaction scores improved by 12 points.
Agricultural Cooperative
Challenge
A Washington state apple grower needed modified gaylords for harvest bins that could handle 1,200 lbs of apples while allowing airflow for cooling and being forklifted from any direction on muddy orchard floors.
Solution
We modified standard 48x40x36 full-bottom DW gaylords with die-cut ventilation holes (2-inch diameter, 6 per side), reinforced double-thickness bottoms rated for 1,500 lbs, and hand-holes on all four sides for manual repositioning. FDA-compliant poly liners were offered for washed produce.
Results
The cooperative replaced 60% of their wooden bins with modified gaylords, saving $3.80 per container per use cycle. The lighter weight reduced fuel costs by 8% on orchard-to-packinghouse runs. Gaylords averaged 4 use cycles before recycling.
Subscription Box E-Commerce
Challenge
A Portland-based subscription snack company needed a monthly-changing branded box that held 8-12 irregularly shaped items, protected fragile chip bags and jars, and created a memorable unboxing experience — all at a per-box cost under $2.50.
Solution
We designed a custom tuck-top mailer in 32 ECT white top kraft with 4-color flexo printing (new design each month, rotating plate sets). Interior uses a corrugated tray with adjustable-height partitions and a kraft tissue paper layer. The box self-locks without tape.
Results
Per-box cost came in at $2.15 at 5,000 units/month. Damage claims dropped 67% compared to their previous stock-box solution. The custom design contributed to a 23% increase in social media unboxing shares and a 9% improvement in subscriber retention.
Medical Device Manufacturer
Challenge
A medical device startup needed packaging for a 6.5 lb diagnostic instrument valued at $4,800. The device required ISTA 3A-validated packaging, ESD protection, temperature stability, and a premium professional appearance for hospital delivery.
Solution
We engineered a double-box system: an inner 44 ECT white box with custom anti-static cross-linked PE foam inserts (CNC-routed to exact device contours), wrapped in a VCI bag. The outer 48 ECT DW shipping box includes thermal insulation panels. Both boxes feature 2-color flexo printing with regulatory markings and lot traceability.
Results
The packaging passed ISTA 3A testing (including the 73-inch free-fall drop) with zero device damage across 20 test units. Per-unit packaging cost is $12.40 at 200 units/month — well within the client target of $15.
Minimum Orders & Turnaround Times
| Custom Service | Minimum Order | Prototype Lead | Production Lead | Reorder Lead |
|---|---|---|---|---|
| Custom die-cut box | 250-500 units | 2-3 days | 7-12 days | 5-7 days |
| Custom foam insert | 25-50 units | 3-5 days | 7-10 days | 5-7 days |
| Molded pulp insert | 500 units | 5-7 days | 14-21 days | 10-14 days |
| Modified gaylord | 10 units | 1-2 days | 3-5 days | 2-3 days |
| Rebranded used box (overwrap) | 100 units | 1-2 days | 3-5 days | 2-3 days |
| Rebranded used box (label) | 50 units | 1 day | 2-3 days | 1-2 days |
| Used box cut-down | No minimum | Same day | Same day | Same day |
| Printed custom box (flexo) | 500 units | 3-5 days | 7-12 days | 5-7 days |
| Printed custom box (litho) | 1,000 units | 5-7 days | 14-21 days | 10-14 days |
| Digital printed box | 50 units | 2-3 days | 5-7 days | 3-5 days |
Rush production available for most services at 15-25% surcharge. Contact us for expedited timelines.
Custom Gaylord Modifications
Our most popular custom service. Standard gaylords are versatile, but targeted modifications make them perfect for your specific operation.
Height Modification
Reduce or extend the standard 36-inch height to match your product and warehouse constraints. Common modifications: 24, 30, 42, and 48 inches. Height changes are made by scoring and cutting — the wall construction remains intact.
From $2/unit for height reduction
Access Doors
Cut drop-front or side-access doors into one or more walls. Doors fold down to create a ramp for loading/unloading with hand trucks or allowing workers to reach into the container without lifting over the wall.
From $4/unit per door
Bottom Reinforcement
Add a second layer of corrugated to the bottom panel for loads that concentrate weight on a small area — sharp-edged products, metal parts, and dense materials. Doubles bottom burst strength.
From $3/unit
Poly Liner Integration
Install a fitted polyethylene liner inside the gaylord for containing liquids, powders, and granular materials. Liners are heat-sealed or fold-over style and available in FDA-compliant grades for food contact.
From $2/unit (fold-over), $4/unit (heat-sealed)
Multi-Compartment Interior
Install corrugated dividers that split the gaylord into 2, 4, or more compartments. Used for sorting different SKUs, separating product types, or creating organized pick stations.
From $5/unit (2 compartments)
Hand-Holes & Ventilation
Die-cut hand-holes on 2 or 4 sides for manual handling. Add ventilation holes for produce, composting materials, or any product that needs airflow. Hole size and pattern are customizable.
From $1.50/unit (hand-holes), $3/unit (ventilation)
Prototyping Services
We never go to full production without a validated prototype. Our prototyping capabilities let you test, refine, and approve designs before committing to tooling.
Sample Table Prototypes
Using our CNC-driven sample-making table, we produce actual-size prototypes from production-grade materials. These are hand-assembled samples that let you test fit, fold, close, and evaluate the design with your actual product. Turnaround: 2-3 business days.
Small-Batch Pilot Runs
For designs that require production-level validation (printed boxes, auto-bottom trays), we run a pilot batch of 25-50 units through production equipment. This catches any machine-related issues before the full run and gives you units for real-world shipping tests.
ISTA Drop & Compression Testing
We offer ISTA 2A and 3A testing protocols for customers who need validated packaging performance. This includes sequential drops from 18-30 inches onto corners, edges, and faces, plus dynamic compression testing simulating warehouse stacking. Full test reports are provided.
Iterative Design Revisions
First prototypes rarely require zero changes. We include up to 3 rounds of design revisions in every custom project at no additional cost. Additional revisions are billed at $75/hour for engineering time. We iterate until you are fully satisfied.
Sustainability Certifications & Practices
Custom packaging does not mean wasteful packaging. We integrate sustainability into every design and offer recognized certifications for customers with environmental reporting requirements.
FSC Chain of Custody
We source FSC-certified corrugated board for customers who need Forest Stewardship Council certification on their packaging. The FSC logo can be printed on your box to demonstrate responsible sourcing to end consumers.
SFI Certified Sourcing
Sustainable Forestry Initiative certified materials are available as an alternative to FSC. SFI certification covers fiber sourcing, forest management, and chain of custody, and is widely recognized in North American markets.
Recycled Content Options
We offer corrugated board with 50-100% post-consumer recycled content. Recycled board meets the same ECT specifications as virgin — the strength comes from the flute geometry, not just the fiber. Certificates of recycled content are available.
Right-Sizing Engineering
Our engineers minimize material usage by design. We select the thinnest board grade that meets your performance requirements, eliminate unnecessary flaps and panels, and design inserts that replace foam with corrugated wherever possible.
Carbon Impact Reporting
For customers tracking Scope 3 emissions, we provide estimated carbon impact data for your custom packaging — covering material production, manufacturing, and transportation. Used-box solutions include avoided-emissions calculations.
Reuse-First Design Philosophy
When your application allows, we design custom packaging from modified used boxes rather than manufacturing new. This approach costs 40-60% less and avoids 90%+ of the carbon footprint of new custom packaging.
Bulk Custom Orders
Custom packaging economics improve dramatically at higher volumes. Here is how quantity affects pricing, lead time, and what we can offer.
Small Run
100-500 units
Ideal for prototyping, limited-edition products, or seasonal promotions. Tooling costs are the primary expense at this level. Simple die-cuts and standard board grades keep costs manageable.
Lead time: 7-10 business days
Mid Volume
500-5,000 units
The sweet spot for most businesses. Tooling is amortized across enough units to make custom packaging cost-competitive with off-the-shelf alternatives. Custom printing and complex die-cuts become economically viable.
Lead time: 10-15 business days
High Volume
5,000+ units
Maximum economies of scale. Per-unit costs approach commodity pricing. Full-color litho-laminate, multi-piece packaging systems, and custom inserts are all cost-effective at this level. Blanket orders with scheduled releases available.
Lead time: 15-20 business days (first run)
Frequently Asked Questions
How much does a custom packaging project cost?
It varies widely based on complexity, materials, printing, and quantity. A simple custom-sized RSC in unprinted kraft starts at $1.50-$3.00 per unit at 500 qty. A full-color litho-laminated die-cut mailer with custom foam insert might run $5-$12 per unit at 1,000 qty. We provide detailed quotes within 24 hours of receiving your requirements.
Do I own the tooling (dies and plates)?
Yes. All tooling produced for your project is owned by you and stored at our facility for up to 2 years at no charge. If you choose to move production elsewhere, we will ship your tooling at no cost. Tooling typically costs $300-$3,000 depending on complexity.
Can you work from a product sample rather than dimensions?
Absolutely. Send us your product and we will measure it, evaluate its fragility and weight distribution, and design packaging around it. This is actually our preferred approach because it lets us account for real-world product variations that drawings may not capture.
What if my product changes after the packaging is designed?
Minor product changes often require only minor packaging adjustments — a new foam insert profile or adjusted divider height. We store your CAD files and can modify designs quickly. If a completely new design is needed, we apply a 50% discount on design and engineering fees for existing customers.
Can you design sustainable custom packaging?
It is our specialty. We design with sustainability as a primary constraint: right-sizing to minimize material, using recycled content board, replacing foam with corrugated or molded pulp inserts, and sourcing FSC or SFI certified materials. We also provide carbon impact estimates so you can measure the sustainability of your custom packaging.
Do you offer packaging design without manufacturing?
Yes. If you have an existing manufacturing partner but need design and engineering expertise, we offer standalone consulting. We provide CAD files, material specifications, dieline templates, and prototype samples that your manufacturer can take directly to production. Consulting fees start at $500 per project.
What is the fastest turnaround possible for a custom project?
For simple modifications (used box cut-downs, gaylord height reductions, label application), same-day turnaround is standard. For custom die-cut boxes with no printing, 5 business days is achievable with a rush surcharge. Printed custom boxes need a minimum of 7-10 business days. We always communicate realistic timelines upfront.
Start Your Custom Project
Describe your product, your packaging challenge, and your target quantity. Our engineering team will reach out with initial recommendations and a rough estimate — typically within one business day.