New Boxes
When Only New Will Do
We are passionate advocates for used packaging — but we also understand that certain applications demand virgin corrugated. Food-grade compliance, brand-printed exteriors, and exact-specification engineering all require new boxes. We supply them at competitive prices with fast turnaround.
When to Choose New Boxes
Food-Grade Requirements
Direct food contact demands virgin corrugated board that has never held other products. Our new food-grade boxes meet FDA and USDA requirements for primary and secondary food packaging.
Custom Branding
Your box is the first thing your customer sees. Custom-printed new boxes with your logo, colors, and messaging create a premium unboxing experience that used boxes cannot replicate.
Exact Specifications
When your product requires a precise internal dimension, specific flute profile, or engineered crush strength, a custom-manufactured new box ensures perfect fit and performance.
Regulatory Compliance
Certain industries — pharmaceuticals, medical devices, hazardous materials — mandate new, untouched packaging with documented chain-of-custody. We supply compliant options.
ECT Ratings Explained
The Edge Crush Test (ECT) measures how much top-to-bottom compressive force a box can withstand before buckling. A higher ECT number means stronger stacking performance. ECT has largely replaced the older Mullen Burst Test as the industry-standard metric for box strength.
| ECT Rating | Max Load | Burst Strength | Wall Type | Flute | Applications |
|---|---|---|---|---|---|
| 32 ECT | ~65 lbs max | 200 psi | Single Wall | B or C | Clothing, linens, plastic parts, paper goods, cosmetics, software |
| 40 ECT | ~80 lbs max | 250 psi | Single Wall | B or C | Subscription boxes, kitchenware, dry food products, office supplies |
| 44 ECT | ~95 lbs max | 275 psi | Single Wall | C | Canned goods, hardware, small appliances, books, beverages |
| 48 ECT | ~120 lbs max | 350 psi | Single Wall or Double Wall | C or BC | Tools, automotive parts, beverages, electronics, machine components |
| 51 ECT | ~140 lbs max | 400 psi | Single Wall or Double Wall | BC or EB | Heavy industrial parts, dense food products, machinery components |
| 61 ECT | ~175 lbs max | 500 psi | Double Wall | BC | Heavy electronics, industrial machinery, fragile equipment, export goods |
| 71 ECT | ~200 lbs max | 600 psi | Double Wall | BC or AC | Automotive assemblies, machine parts, industrial chemicals, heavy export |
Box Style Guide
Corrugated boxes come in many styles beyond the standard RSC. Each design serves specific functional and aesthetic purposes. Here is a comprehensive guide.
RSC (Regular Slotted Container)
The most common box style. All four flaps are the same length and meet at the center. Simple, economical, and versatile. Works for 80% of shipping applications. Available in every ECT rating and size.
Best for: General shipping, storage, e-commerce
Min order: 25 units (standard), 100 units (custom size)
HSC (Half Slotted Container)
Bottom flaps only — open top. Used with a separate lid for easy access or left open for display and pick-and-pack operations. Popular in warehousing and retail.
Best for: Warehouse bins, display packaging, easy-access storage
Min order: 50 units (standard), 250 units (custom size)
FOL (Full Overlap)
All flaps extend the full width of the box and overlap completely when closed. Creates a double-thick top and bottom for extreme stacking strength and moisture resistance. Heavier and more expensive than RSC.
Best for: Heavy items, long-distance freight, extreme stacking
Min order: 100 units (custom only)
Die-Cut Mailer
One-piece design that folds into a self-locking tuck-top box. Opens like a book for a premium unboxing experience. No tape required. Available with full-color printing for brand impact.
Best for: E-commerce DTC, subscription boxes, premium retail
Min order: 250 units (simple), 500 units (printed)
Telescoping Box
Two-piece design with a separate lid that slides over the base. Provides adjustable height and superior protection for flat or thin items. Excellent stacking performance.
Best for: Framed art, mirrors, flat electronics, documents
Min order: 100 units
Auto-Bottom Tray
Pre-glued bottom that pops open and locks into place without tape. Dramatically speeds up packing operations in high-volume environments. Top flaps fold closed normally.
Best for: High-speed fulfillment, food packaging, produce trays
Min order: 500 units
Five-Panel Wrap
A flat sheet that wraps around the product and tucks closed. Adjustable to different product thicknesses. Used for flat items like books, frames, and panels.
Best for: Books, picture frames, flat panels, mirrors
Min order: 100 units
Partition / Cell Box
An RSC or HSC with built-in corrugated dividers that create individual cells. Protects multiple items from contact damage. Die-cut partitions lock into the box walls for stability.
Best for: Bottles, jars, glassware, electronics components
Min order: 250 units (box + partition set)
Retail-Ready / Shelf-Ready
Shipping box that converts to a display with perforated tear-away lid and graphics. Goes from truck to shelf without repackaging. Reduces retailer labor costs and speeds up restocking.
Best for: Retail distribution, grocery, convenience stores
Min order: 1,000 units (printed)
Material Specifications
Understanding board materials helps you choose the right box for your application. Here are the key material options available for new boxes.
| Material | Liner Type | Color | Best For | Cost |
|---|---|---|---|---|
| Virgin Kraft | Kraft (K) | Natural brown | Maximum strength, industrial use, export | Standard |
| Recycled Kraft | Test (T) | Brown (variable) | General shipping, storage, cost-sensitive | Lower |
| White Top Kraft | White Kraft (WK) | White exterior | Premium appearance, printing, retail | Higher |
| Oyster White | Mottled White (MW) | Off-white | Mid-range appearance, light printing | Moderate |
| Wax-Coated | Wax-impregnated | Brown/white | Moisture resistance, cold storage, produce | Premium |
| Water-Resistant | Poly-coated | Brown/white | Outdoor exposure, refrigerated shipping | Premium |
Printing & Branding Options
Unprinted (Plain)
Brown kraft or white exterior with no printing. The most economical option and the fastest to produce. Ideal for internal use, B2B shipments, or when you apply your own labels.
Lead time: 1-2 days | MOQ: 25 units | Cost: Lowest
- Available in kraft brown or white exterior
- No setup fees
- Fastest production time
- Best per-unit cost at any quantity
1-2 Color Flexographic
Direct flexographic printing on the box exterior. Cost-effective for logos, handling instructions, and basic branding. One or two PMS colors on kraft or white board.
Lead time: 5-7 days | MOQ: 500 units | Setup: $250-$500 per color
- Up to 2 PMS (Pantone) spot colors
- Print area up to 60% of panel face
- Resolution: 85-133 lpi (line screen)
- Plate costs amortized over quantity — reorders are cheaper
3-4 Color Flexographic
Extended flexographic printing for more complex branding. Allows for detailed logos, product imagery (limited), and multi-color designs directly on corrugated.
Lead time: 7-10 days | MOQ: 1,000 units | Setup: $350-$700 per color
- 3-4 PMS spot colors
- Process color (CMYK) available on white board
- Full panel coverage possible
- Best balance of cost and visual impact
Full Color Litho-Laminate
High-definition full-color printing laminated to the corrugated board. Produces retail-quality graphics with photographic detail. The premium option for maximum brand impact.
Lead time: 10-15 days | MOQ: 1,000 units | Setup: $1,500-$3,000
- Full CMYK + spot colors
- Photographic quality (175+ lpi)
- Glossy, matte, or soft-touch finishes available
- Ideal for shelf-ready and premium e-commerce packaging
Minimum Orders & Lead Times
Lead times and minimums vary by box style, printing, and customization level. Here is a comprehensive reference.
| Product Type | Minimum Order | First Order Lead | Reorder Lead | Setup Cost |
|---|---|---|---|---|
| Standard RSC (stock size) | 25 units | 1-2 days | 1-2 days | None |
| Standard RSC (custom size) | 100 units | 5-7 days | 3-5 days | $0-$150 |
| Die-cut (simple) | 250 units | 7-10 days | 5-7 days | $300-$600 |
| Die-cut (complex) | 500 units | 10-14 days | 7-10 days | $600-$1,200 |
| 1-2 color printed | 500 units | 7-10 days | 5-7 days | $250-$500/color |
| 3-4 color printed | 1,000 units | 10-14 days | 7-10 days | $350-$700/color |
| Litho-laminate | 1,000 units | 14-21 days | 10-14 days | $1,500-$3,000 |
| Auto-bottom tray | 500 units | 10-14 days | 7-10 days | $400-$800 |
| Retail-ready / SRP | 1,000 units | 14-21 days | 10-14 days | $800-$2,000 |
Rush production available for most products at 15-25% surcharge. Contact us for expedited timelines.
Industry-Specific New Box Solutions
Food & Beverage
FDA-compliant virgin kraft board for direct and secondary food contact. Wax-coated options for moisture resistance. SQF and BRC-compatible manufacturing. White interior liners available for produce and bakery.
E-Commerce & DTC
Custom-printed mailer boxes with full-color litho-laminate for premium unboxing. Self-locking designs eliminate tape. Right-sized to minimize dimensional weight charges from carriers like UPS, FedEx, and USPS.
Pharmaceutical & Medical
Clean-room compatible packaging with lot traceability. Tamper-evident closures. Temperature-insulated options with EPS or VIP liners. Child-resistant designs. Full regulatory documentation included.
Electronics & Technology
Anti-static corrugated options (ESD-safe) for sensitive components. Custom foam inserts with exact product contours. Drop-test validated designs per ISTA 2A/3A protocols. Full-color retail packaging.
Wine & Spirits
Cell-partition boxes for 6-pack and 12-pack configurations. SBS (solid bleached sulfate) or litho-laminate exterior for premium shelf presence. Molded pulp inserts for individual bottle protection.
Industrial & Heavy Parts
High-ECT double-wall and triple-wall construction for heavy machined parts, castings, and assemblies. VCI (Vapor Corrosion Inhibitor) liners for rust prevention. Custom foam cradles for precision components.
Design Services
Our in-house structural and graphic design team helps you create the perfect box — from initial concept to production-ready artwork. All design services are included with qualifying orders.
Structural Engineering
Our engineers select the optimal board grade, flute profile, ECT rating, and box style for your product weight, fragility, and shipping conditions. We use TOPS (Total Optimized Packaging Solutions) software to model stacking performance and transit hazards before cutting a single die.
Graphic Design & Prepress
We create print-ready artwork from your brand guidelines, or design from scratch if needed. Our prepress team ensures color accuracy, proper bleed and registration, and corrugated-specific adjustments like dot gain compensation for flexographic printing.
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 print quality, and run shipping trials. ISTA drop and compression testing available for validated designs.
Dieline Templates
We provide precise dieline templates (in AI, PDF, or DXF format) so your design team can create artwork that aligns perfectly with score lines, fold points, and print boundaries. Templates are free with any new box order.
New vs. Used: Decision Guide
Not sure whether new or used boxes are right for your application? Use this decision matrix to find the best fit.
| Requirement | Choose New | Choose Used |
|---|---|---|
| Direct food contact | Required (FDA compliant) | Not suitable without liner |
| Custom printing / branding | Full printing options available | Labels/overwrap alternative |
| Exact custom dimensions | Manufactured to spec | Cut-down service available |
| Lowest possible cost | Higher per-unit cost | Save 40-60% |
| Fastest delivery | 1-2 days (stock), 5-21 days (custom) | Same day (in stock) |
| Environmental priority | New fiber + manufacturing | Zero manufacturing, ~90% less CO2 |
| Customer-facing shipment | Clean, brandable exterior | Grade A is near-identical to new |
| Pharmaceutical / medical | Required (chain of custody) | Not suitable |
| Warehouse / internal use | Works but more expensive | Ideal — Grade B/C saves most |
| Hazmat / dangerous goods | UN-certified options available | Not certified for hazmat |
Volume Discounts
The per-unit cost of new boxes drops significantly at higher quantities because setup and tooling costs are amortized across more units. Here is a general pricing framework — exact quotes depend on size, ECT, and printing.
| Quantity | Typical Discount | Lead Time | Notes |
|---|---|---|---|
| 1-99 | List price | 1-2 days | Standard sizes only |
| 100-499 | 5-10% off | 2-5 days | Custom sizes available |
| 500-999 | 10-20% off | 5-7 days | Printing available |
| 1,000-4,999 | 20-30% off | 7-10 days | Best value for printed boxes |
| 5,000+ | 30-40% off | 10-15 days | Full custom, best per-unit cost |
Frequently Asked Questions
What ECT rating do I need for my product?
As a rule of thumb: 32 ECT for items under 20 lbs, 44 ECT for 20-50 lbs, 48 ECT for 50-80 lbs, and 51+ ECT for anything heavier. However, box size, stacking height, and shipping distance also matter. Tell us your product weight and how high you stack, and we will recommend the optimal rating.
Can you match my brand colors exactly?
Yes. We print using PMS (Pantone Matching System) spot colors, which ensures consistent, repeatable color across every production run. For litho-laminate printing, we use ICC color profiles calibrated to our presses. We provide press proofs for approval before full production.
What file formats do you accept for artwork?
We accept Adobe Illustrator (.ai), PDF, and EPS files with text converted to outlines and images at 300+ dpi. We provide dieline templates in your preferred format so your designer can place artwork precisely. If you do not have a designer, our in-house team can create artwork from your brand guidelines.
Do you offer food-safe / FDA-compliant boxes?
Yes. Our food-grade boxes are manufactured from virgin kraft fiber in SQF-certified facilities. They meet 21 CFR 176.170 (FDA indirect food contact) and USDA requirements for direct food packaging. Certificates of compliance are available with every order.
What is the difference between flexo printing and litho-laminate?
Flexographic printing applies ink directly to the corrugated board using rubber plates. It is cost-effective but limited to 1-4 spot colors at 85-133 lpi resolution. Litho-laminate prints on a smooth paper sheet first (at 175+ lpi) and then laminates it to the corrugated, producing photographic-quality full-color graphics.
Can I order a small quantity to test before committing to a large run?
Absolutely. We encourage test orders. For standard sizes, you can order as few as 25 units. For custom die-cuts and printed boxes, we produce sample quantities (typically 25-50 units) at a slight premium to cover tooling, so you can test fit, ship trial units, and get customer feedback before scaling up.
Do you keep dies on file for reorders?
Yes. We store all dies and printing plates for at least 2 years after the last order. Reorders skip the tooling phase entirely, reducing lead time by 3-5 days and eliminating setup costs. We recommend reordering before your stock runs out to avoid gaps.
Before You Order New — Consider Used
We stock thousands of used corrugated boxes in all standard sizes, graded and inspected. For the vast majority of shipping, storage, and internal-use applications, a Grade A used box is functionally identical to a new one — at 40-60% of the cost and with a dramatically smaller environmental footprint.
Reusing a box avoids the ~0.7 kg of CO2, ~80 liters of water, and the tree fiber required to manufacture a new one. If your application does not strictly require virgin board, choosing used is the smarter financial and environmental decision.
Explore Used Boxes →Request a New Box Quote
Tell us the size, ECT, quantity, and printing requirements. We will deliver a detailed quote with lead times and volume pricing options.