Custom Packaging 101: Everything First-Time Buyers Need to Know

Getting a package feels like getting a present. It activates the same mood-boosting hormones like serotonin and dopamine that ramp up during retail therapy. Brands can easily increase this joy factor by providing a bespoke unboxing experience. 

Packaging is part of what keeps customers coming back over and over again, and the best custom packaging for small businesses is immediately recognizable and builds customer trust. Creating unboxing excitement and customer retention is possible through custom packaging.  

What "Custom Packaging" Actually Means

Custom packaging is tailored to your business through art, branding, size, materials, and inserts. There are different levels of customization, ranging from fully custom sizing to basic templates, and even retail-grade options like SBS packaging used for product and presentation boxes. 

For example, Stitch Fix uses a relatively simple, templated design that includes basic branding and paper wrapping; meanwhile, Scentbird uses tailored packaging with exact product inserts and full-color design.

The Best Custom Packaging for Small Business: Your Core Options

For every product and brand, there is a packaging solution. 

• Custom Mailer Boxes: Choose these when you’re shipping lighter products (apparel, small retail items, subscription kits) and you want the unboxing experience and branding to matter as much as the delivery.
• Custom Shipping Boxes: Pick these when your items are heavy or fragile, and transit protection is the top priority, while still keeping your brand visible.
• Triangle Document Box Mailers: Use these when mailing posters, blueprints, or artwork because they protect flat/rolled documents better than tubes and won’t roll during handling.
• Custom One Piece Folder Boxes: Select these for thin, flat items like books or certificates when you need quick packing and minimal packing materials.
• Custom Box Inserts: Add these when you need internal structure for specific products.

Materials 101: What First-Time Buyers Need to Know

The most common material options are corrugated and paperboard. Corrugated boxes are made with a fluted middle layer sandwiched between two liner boards, creating air pockets that absorb shock. Paperboard boxes are made with a single, thick sheet of paper stock with no internal fluting.

Paperboard is less durable and better suited to shipping short distances. Corrugated boxes are much more durable and long-distance friendly. There are two common types of corrugation to choose from: 

• E-Flute: Better for lightweight items. Solid strength and crush resistance in mailer boxes.
• B-Flute: Better for heavier products. Greater durability and protection during shipping.

A packaging partner like Box Genie uses fully recyclable corrugate made from recycled material.

Printing Basics: How to Choose the Right Method

You don’t need print-industry knowledge to understand box printing; you just need to know how each method affects aesthetics and order size/cost. The most common printing options are:

• Digital Printing: artwork is printed directly onto the box without creating plates or tooling.
• Flexographic Printing: rubber printing plates transfer ink onto the corrugated sheet, similar to a stamp.
• Lithographic Printing: the initial high-resolution print on paper is laminated onto the box.

Digital print means no print plate fees and unlimited artwork options. It’s typically a cheaper print option and is capable of a smaller Minimum Order Quantity (MOQ) since there’s no printing transfer requirement. This makes digital well-suited for a wide range of small businesses. 

At Box Genie, we offer 100 units to start, volume discounts, and easy-to-follow packaging templates to help businesses with the design process. 

How to Get Custom Packaging Without Overspending

These are the main cost drivers for your custom packaging. 

• Size: Larger package production requires more materials and time. 
• Material: A basic corrugated material will cost less than a higher-end option. 
• Print Type: As mentioned, the method of printing affects price, as does the number of printing sides (outside and/or inside).  
• Order Quantity: Bulk orders can help businesses save on large orders. 

Box Genie lets small business owners play around with pricing options with real-time, on-site pricing estimates. It’s easy to see how changing dimensions or larger orders can save you money. 

Pricing also scales with your business, with larger orders qualifying for volume-based discounts, and our price-match program keeps you competitive as you grow. For brands focused on keeping costs down, Kraft material is usually the most cost-efficient option while still maintaining durability and clean branding.

The Step-by-Step Packaging Ordering Process

The ordering process is much easier than you may assume. The steps are as follows:

1. Determine your product and protection needs
2. Measure properly
3. Select materials and styles
4. Request a dieline and design your artwork
5. Review proof and finalize
6. Review production and shipping timelines

Common Mistakes First-Time Buyers Make (And How to Avoid Them)

The best custom packaging for small businesses starts with the right packaging partner and strategy. Familiarize yourself with these common mistakes and develop a packaging plan that works for your business.  

• Choosing Low-Quality Suppliers: Work with a packaging partner that offers clear communication and predictable lead times. Look for quick, reliable customer support, too.
• Ordering Too Small Or Too Large: Start with a manageable quantity that covers roughly 1 to 3 months of shipments, then reorder once you understand your actual usage rate and seasonality.
• Not Checking Postal Requirements: Review your carrier’s size tiers and weight limits and design your packaging so it stays within standard shipping categories whenever possible.
• Ignoring Unboxing Experience: Add simple touches such as interior print or a properly fitted insert so customers immediately recognize your brand and remember the purchase.

How Custom eCommerce Boxes Support Growth

Great packaging creates a positive customer experience. It may be a customer's first physical interaction with your brand, and the right size, material, and print method all work together to reinforce trust and make the unboxing memorable. The right custom box company also reduces shipping damages and costs. 

Custom small business packaging simplifies fulfillment and makes reorders easier as your company grows. It’s endlessly scalable and customizable. With the right packaging partner, you can launch professional packaging without tying up cash flow or storage space.

The goal is to order the right packaging for your stage of business. Start simple and refine over time to develop packaging that evolves alongside products and customer needs.

Request an instant quote today and start building packaging that supports your growth.