We are very well known for the millions of die cut mailers we make for DTC shipping. However, what many people don’t know is that we also sell millions of paper and paperboard mailer envelopes. In addition, we also make truckloads of custom size and custom printed RSC shipping boxes for e-commerce applications.
The fact is that RSC style shipping boxes have some distinct advantages including lower cost per box, lower print plate costs and unless the RSC must be die cut for any reason, there are usually no cutting dies required.
Unlike die cut mailers that open like a cigar box with an attached lid at the back, RSC boxes have four flaps on top and bottom and are usually sealed with adhesive or more likely, two strips of tape. This is your standard shipping box or sometimes called a moving box.
The two flaps on the longer side are called the major flaps and the two on the shorter side, usually on the width are called the minor flap. Unless the box is square (12” X 12” for example) the majors meet in the middle and the minors are shorter, so they do not meet in the middle creating a gap between them on the inside of the box.
Available variations include “all flaps meet” and/or “FOL” (full overlap) of either minor or major flaps.
Aren’t flaps just redundant, unnecessary packaging?
Contrary to what some people believe, RSC flaps and variations of them provide many benefits including:
They protect the product being shipped with additional cushioning and strength. Especially with FOL or all flaps meet construction, you create a double wall box on top and bottom giving the box superior corner protection.
They can eliminate the need for additional top and/or bottom reinforcing support pads.
Extending the minor flaps eliminates the gap in between which means products like vertical bottles will stand upright and even.
We often recommend FOL boxes especially for larger, wholesale or retail or orders. Since most people open an RSC with a knife by cutting between the major panels, items like soft goods and apparel are especially vulnerable to accidental cutting. Some people add corrugated board pads to provide this protection but, usually extending the major flaps can do the same job at a lower cost.
We don’t sell boxes; we sell packaging solutions.
The point is don’t mistake the RSC boxes we make for our customers as the same boxes you pick-up at the office supply place or order from stock on the internet. What we offer is custom RSC box designs that are effective and will reduce your overall costs.
Our boxes are not two clicks away, we want to know what you are shipping, how you are shipping it and other details about your specific requirements. Every amazingly low-cost box we sell is made especially for our customers. In fact, we have NO stock RSC boxes to offer, not even unprinted ones on our online green packaging store www.GlobeGuardProducts.com .
If you have a simple, basic application and you want unprinted RSC boxes, there are probably thousands of places where you can buy them. However, if you want a box that is custom printed beautifully and is engineered to satisfy YOUR needs, call us at 630-551-1700 or contact us at Salazar Packaging. Our experienced branded packaging advisors are eager to provide you with a no cost, no obligation consultation.
There is probably no faster growing segment in the custom printed e-commerce box printing business than digital printing direct to corrugated. It is also the one area where many potential customers get confused due to the many variables and options available to them. Their most common questions include:
Long run versus short run? There are basically two different types of digital printing equipment available. They are very different equipment types, creating distinct looks with varying capabilities.
Flexographic versus digital printing? Which is the best option for you?
Matte finish or gloss? Not all printers or digital printing equipment are alike.
Board type? Options range from Kraft to Kemi coated clay board for optimal printing results.
So many digital printing questions, so little time.
However, we have determined that we cannot give this box printing option the time and attention it deserves via those sites, and it really requires a dedicated blog. We are pleased to announce we have added a new blog to our www.DigitalBoxPrinter.com web site.
Check out our newest blog. We can share and focus on this new and everchanging printing process. The purpose is to educate and inform by providing the latest developments in digital ink, board, and equipment
Your Source for Transparent and Accurate Information
This is the most recent addition to our long list of resources we openly share with the industry and our customers. Our objective is always to be a trustworthy, dependable partner, helping you to make the best-informed packaging decisions possible.
As always, do not hesitate to call us at 630-551-1700 or contact us by email at Salazar Packaging. Our very knowledgeable, experienced branded packaging advisors are ready and willing to answer any specific questions you may have.
Salazar Packaging introduces economical stock and custom printed shipping boxes for wine bottles
We have received inquiries and phone calls for years from people interested in packaging for shipping bottles of wine as gifts, order fulfillment, wine clubs, etc. To be frank, we have avoided that packaging application because the challenges of shipping glass bottles are numerous. With many recent successes in shipping other glass products such as liquor and candles, and after months of designing, ship testing, and tweaking, we believe we have come up with a terrific and effective packaging solution.
Until now, the available packaging options for glass wine bottles have been few:
RSC boxes with foam inserts – effective but not very green, creating a foam disposal problem.
RSC style boxes with molded pulp inserts – effective and green but not very attractive, delivering a poor unboxing experience.
In addition, both options tend to be costly and not brandable. Can you imagine trying to custom print on a molded pulp or foam insert?
The Globe Guard ® wine shipper is 100% eco-friendly.
Our box and insert combination are both made of a minimum of 40% recycled content and can be easily broken down for recycling at curbside or anywhere paper waste is processed. 100% recycled content is an available option, but it is one we would have to discuss including your graphics required. Print-ability differs on board grades and types and we want to make sure we provide you with the best look possible.
Our design team spent hours developing the smallest, most lightweight design that is still going to protect the product being shipped. This reduces waste and shipping costs inbound and outbound.
Custom Printed Wine Shipper
Our wine shipper design is versatile.
Our standard (die cut mailer) box and insert are designed to handle two of the most common bottle diameters (2-3/4” to 3”) and three of the most popular bottle heights of 8-1/2”, 8-3/4” and 9”. Die cut mailers are referred to as “presentation boxes” because they open with an attached lid for maximum positive visual impact for the recipient.
Custom sizes and designs are also available for different wine and liquor bottles with other shapes, diameters, and lengths.
The Globe Guard ® wine shipper features a unique insert to present and protect
Our two-piece insert design assembles quickly without glue or tape. It provides an air cell completely around the bottle being shipped to insulate and help protect it from transferred drop shock. No packaging used for shipping glass is guaranteed because of the many packing variables and we all know how brutal some shipments can be whether you use FedEx, UPS, or USPS. We have conducted numerous drop tests and ship tests and our design has performed extremely well under many typical e-commerce shipping scenarios.
Equally important as protection is presentation. Our insert and box design is designed to create an exceptional unboxing experience. Unlike other protective shrouds, bags or bubble wrap, the bottle and wine label are completely visible, and all components are brandable with flexographic, digital or even offset printing. Branding is available for inside and outside of the mailer as well as the insert. See a small sampling of our custom printing work in the gallery of our website.
Wine Shipper in Natural Kraft
Program details under development
The minimum for any of our boxes and inserts, unprinted or custom printed, is 1,000. We are considering at some point offering a stock, unprinted version that will be available on our Globe Guard Products green packaging store in smaller quantities, but we are not there yet. Where we go and what we do will be driven by customer response.
We encourage every customer to conduct their own ship test prior to placing a larger order to make sure your bottle design and our shipper are compatible.
If you would like a quote, we would need the following information:
Bottle diameter at base and neck.
Bottle height overall and specifically the neck from shoulder to cork end.
Mailer box and insert board colors: white or Kraft board, inside and/or out
If printed, some idea of the graphics you have in mind
Also, most importantly, order quantity
Let us know if you have any questions by emailing Salazar Packaging or calling us at 630-551-1700. This is an exciting new product for us because we are confident it will satisfy many requirements for our clients and customers.
We are all familiar with USPS, UPS or FedEx corrugated shipping boxes that feature a peel and seal strip for security and fast, easy (tapeless) closure. In most cases a peel and seal adhesive strip is accompanied by a tear strip for easy opening by the recipient.
Until recently, this type of box was unaffordable for the average shipper because of high costs per box and even higher minimums. That is why shippers who want this design feature end up having to use the USPS, UPS and FedEx “free” boxes those carriers are eager to provide. This link will lead you to the post that discusses the true cost of those free boxes; it may be more than you think. However, my biggest problem with them is that they are printed to promote their name and brand, not yours.
We are pleased to announce we can now offer that style of box with one adhesive and easy open tear strip. We believe the only thing better than one adhesive strip is two strips, because it is an inexpensive way to create a box the consumer can open, reseal and return product that is the wrong size, color, etc.
Two Way (Returnable) Packaging
In some applications (apparel for example) having a box that can be shipped back with a return, exchange, etc. is very desirable because it reduces the possibility of the clothing being soiled or damaged in the process. An example is online rentals of onetime use apparel like formal gowns, tuxedos, as well as e-commerce companies whose business model is returning and exchanging outgrown clothing gently worn by fast growing children. Whatever the application or reason for the return, the customer convenience is good for them and for you.
A NEW product from Salazar Packaging
We can apply one or two “peel and seal” adhesive strips on almost any size shipping mailer box. If only one adhesive strip is necessary, you can still have a reinforced easy open perf for customer convenience. If you need a two-way (returnable) shipper, we apply two adhesive strips with a reinforced tear strip in between.
Combine this with our ability to custom print your box inside and out with YOUR brand, and custom inserts to present and protect the product being shipped, and we can now deliver a complete and unique package design your customers are sure to appreciate.
Some special tooling (onetime expense) may also be necessary depending on the size, style, and feature you want. Generally, the minimum is usually in the 1,000 to 3,000 range depending mostly on the box size and graphics required.
We can look at the complete application and give you a firm price that is likely to surprise you. Packaging like this is more affordable than you might think.
If you are interested in this new product and have any questions, please do not hesitate to contact us by phone at 630-551-1700 or by . We are the company that makes “packaging that communicates” and we are confident this new capability will say great things about you.
One of the great delights of doing what we do is watching companies launch, grow, and succeed. A few have even become huge success stories: appearing on shows like Shark Tank, Ellen and Stephen Colbert, and business magazines features. A few of those companies have eventually been acquired for millions of dollars.
The old adage, if you are not moving forward, you are falling behind is absolutely true. It happens when other companies learn from what you have accomplished and how you did it. They want your market share and if you are not a fast-moving target, you may be easily caught and passed up.
Is your e-commerce packaging up to date?
Much like your computer, if your packaging is more than a few years old, it is probably out of date. Your competitors have copied and even improved on your packaging by adding new features and better graphics. What was new and exciting a few years ago has become tired and maybe even a little boring.
A few questions to ask yourself.
How does my packaging compare to my top three, high profile competitors?
Am I as happy with it as I was when we first launched it?
What does my packaging communicate?
Does it reflect the company we are today?
Has my packaging kept up with my other marketing such as logos, company colors, graphic designs, etc.?
Are my box sizes appropriate and fit my products properly?
An insight based on working with thousands of entrepreneurs.
First, let me say, if you did not like your answers to the questions above – it is NOT your fault. You have been busy trying to build a business and have been on an incredible learning adventure, perhaps for years. You’ve overcome many hurdles, and after the usual amount of self-doubts along the way, you have endured and are now finally beginning to reach a level of success and profitability. Your packaging design has not been “broke” so it has not required “fixing”. However, your new goal is to get to that next level, and to get there you are possibly contemplating a packaging rebranding and/or redesign.
DTC Packaging Presentation and Performance!
Sometimes, it is all about aesthetics and the unboxing experience. In other situations, it is as much about functional performance. Size and configuration questions are two practical reasons driving packaging changes. Since you launched your business, your product’s sizes and shapes may have changed. Your configurations and counts may have evolved as well.
Now your box may be a little too tight or more likely, too large, requiring additional void fill. Many new companies tend to initially oversize their packaging “just in case”. Combine that with smaller product or order sizes and your packaging is costing you much more than it should in terms of purchase price, storage space, and shipping cost.
Are you shipping in the lowest possible tier? You may find this this post interesting about dimensional weight shipping. Modifying and reducing your box size less than an inch MAY save you as much as two dollars per box. Perhaps that was not a big deal when you were shipping a handful of boxes, but now that is probably a big, substantial cost savings.
Brand Identify – a self-taught lesson
Below is a photo of one of our initial business cards. You can see where the original plan was to focus on what my wife and I knew best – flexible packaging, AKA plastics. It did not take us long (within our first year) to determine our logo was not getting great reviews, the company name was too long, and we really had no desire to promote plastics. Customers were asking for greener products and eco-friendly packaging became our new primary product with branded close behind it. In short, our “brand” really did not reflect who we are and what we offer. We made the decision to rebrand and probably owe our success to that single decision.
One of the great advantages we all have as a new, small business is that we can make decisions and implement them quickly. If that does not work, try something else because we can change course at will. Coming from a large company, corporate environment, I now recognize that flexibility and speed to market may be our greatest advantage against older, larger competitors. Years ago, we coined a phrase “eco-consistent packaging”. It was not a revelation to us; it was simple advice to make sure your packaging reflects who you are and what you do. Sadly, it often does not but the good news is you can always change that.
If you are ready to at least discuss a redesign or rebranding, we are the right company to engage. We have helped to create and re-create millions of boxes over the course of the last 12 years and we can save you time and money while producing a box that fits perfect and looks great.
Call us at 630-551-1700 or contact us at Salazar Packaging. We also invite you to visit our gallery where you will see a small sampling of our work and the companies who trusted us, sometimes with their first box and in other situations, with their redesign.
Launching a new branded shipping or subscription box requires several decisions; box style and dimensions, insert design (if necessary), and the key decision, what do I want it to look like? Printed in, and/or printed out, and most important of all, what colors do I want to use? Flood coat or minimal coverage?
Certainly, a good graphic artist will be invaluable if they understand the advantages and limitations of flexographic printing (see related posts below). That is when an experienced packaging designer like Salazar Packaging can save you a tremendous amount of time and money by providing great insight on does and does not work. We can help guide you and your graphic artist to the best possible print job at minimal cost.
Here are a few questions frequently asked about ink, colors, and graphic designs:
Are all box printing inks eco-friendly?
Some are not but most are. However, ALL the inks we use are water based and considered eco-friendly. The rule of thumb is to keep it simple. The more complex you make your box with varnishes, coatings, labeling, etc., the less likely the board will remain green. Corrugated board is made green by nature, but what we do to it may take us in the opposite direction.
What is the most popular color for e-commerce and subscription boxes?
There are many popular ink colors, and some are very simple such as black or white that both look great on Kraft board. Others are more sophisticated such as pastels or very bold, bright colors. Some Pantone colors are trendy such as Living Coral, which is the hot color for 2019, but last year in 2018 it was Ultraviolet. We believe the key is making sure your color blends well or sharply contrasts with your company colors and logo. Your DTC box color should also reflect who you are and what you do. Don’t worry, if we believe you may be making a color choice mistake, we will tell you.
Do all colors print the same?
This is a great question we hear often, and the answer is no, they do not. Colors tend to print slightly differently depending on the substrates and ink formulations. I often refer to direct printing on corrugated as an imperfect process on an imperfect substrate. As great as today’s equipment is, there are two things that we cannot control. One is the natural Kraft (brown) board color variations and the porosity or ink absorption rates.
Like no two trees are the same color, no two corrugated sheets are identical. On high recycled content corrugated board, the color varies even more due to the specific mix of recycled materials. That is why we prefer to print some colors on white board rather than Kraft, especially flood coats.
Corrugated is sponge-like in that it tends to absorb ink in dry weather and climates, leaving less ink visible on the surface. In higher humidity conditions, ink is not absorbed as deeply, and ink colors appear fuller or denser.
How much more expensive is printing two colors compared to one color?
The fact is that printing two colors is only slightly more expensive compared to one color. In most cases it is less than a few cents or 5% difference. Set up time (1 versus 2 colors) is almost identical and water-based inks are relatively inexpensive. The only additional cost is the ONETIME cost for a second print plate that typically runs between $400 and $600.
What is the price difference between one- and two-sided custom printing?
Printing the outside of a box is relatively inexpensive because it is printed simultaneously when the box is being die cut. However, printing inside adds 20 to 30% because it requires a second pass through the same machine.
There is some great news coming later this summer that we will have equipment able to print inside and out on a single pass. That will dramatically reduce the cost of this now “must have” print option.
I really want but can’t afford inside printing at this time.
That is a common problem and it is wise to not spend more than you can at the start-up stage of your business. Any inside print can be added anytime in the future when you are ready. See this post for more info.
These are just a handful out of hundreds of questions we have been asked over the course of the last twelve years. If we have not covered yours, please contact us at Salazar Packaging or call us at 630-551-1700. One of our branded packaging advisors or I will be glad to help you determine the best path forward for your specific product and application.
We are very sensitive to the fact that many of our customers are start-ups or are launching new sites and new products so cash flow may not be positive at this stage. We strive to make sure the customer is well informed on all their options now which may help them to avoid an unanticipated, costly makeover of their new packaging.
That is why we don’t have a plug and play type site where people can design their own boxes, usually with no help whatsoever. We insist on getting involved in the design process because after creating millions of boxes for thousands of customers, we may have an idea or two that will set your box apart form the rest, at MINIMAL cost. Most people are surprised at how little cost difference there is between a good e-commerce box or a great one that becomes a star on Instagram or other social media sites.
Here are a few available features and options as well as ballpark cost percentages, but keep in mind cost for any box or feature is determined by many factors, especially size, graphics, and order quantity. The goal is always to help you create a unique, awesome e-commerce or subscription box, at minimal cost.
Available E-commerce Box Features
DTC Box closure options– You can check out this post but there are several design options available to you. The best part is that usually they add ZERO additional cost.
Custom Printed Boxes with a Second Color– There are limitations on what is or is not possible (see this post) and of course a second color requires a second print plate if printing flexo, but the second color (same side) price difference is usually less than 5%.
Right size your DTC box – The interesting thing about this suggestion is that it usually results in a cost SAVINGS. Customers always tend to oversize their boxes “just in case” so right sizing saves money in several ways. See first “related post” below.
Inside printing on an E-commerce Box – this is one of the more expensive options on any box (usually 20 to 30%) but it delivers a great customer experience. If that cost is out of range right now, keep in mind we can always add inside print later. See second related post below.
Custom Inserts for DTC boxes – Custom inserts protect and present your products better than any bubble, foam or loose void fill. They can also be printed (see this post) and the costs vary greatly, but they can save a lot of money in terms of labor and damage prevention. Much like inside printing, it can always be added in the future as your business grows.
Peel and seal strips for tapeless box sealing- usually combined with easy open perforations and tear tape making the unboxing quicker and safer. They can add as much as 20 to 30% to the cost on a box (depending on size and order quantity) but on a box costing $.80 is it worth sixteen cents to prevent customer injury or product damage while opening, and reduce cost on manual taping? Learn more at the third (related post) link below.
These are just a few of the options we are prepared to discuss with you but remember, a good magician never shows all his tricks and as many of our customers will tell you, we perform magic on DTC and subscription boxes. Check out our gallery to see just some of the work we have done and the companies we have had the honor of serving.
Contact us via email or call us at 630-551-1700 to speak with one of our experienced, well trained branded packaging advisors. We look forward to learning more about your product and e-commerce application.
I should probably thank USPS for the continued interest in e-commerce boxes that have a peel and seal adhesive strip and an easy open perforated tear strip, because they have been offering these to the public for years. After all, many of the people we work with launched their internet companies using those “free” USPS boxes. So, when they grow and move to our custom branded boxes, they miss the speed and convenience of the USPS boxes with those specific features.
What’s wrong with using USPS e-commerce boxes?
If you are interested in promoting your brand, rather than USPS’s brand, you need a company like ours that can provide beautiful branded boxes with your logo and colors printed on them. In addition, USPS will not make a custom size for you and they don’t offer protective, display inserts which is what we specialize in. No need for extra void fill material to prevent the product from rattling around loose in an oversized box. The benefits of right sizing are numerous as detailed in this linked post.
However, the best reason for using a custom printed mailer box is that (depending on what you are shipping and how much it weighs) you avoid paying a premium for their “free” box. The first related post below details the shipping cost difference between a free USPS flat rate box and our own version that we call a Light Rate box. Generally, the lighter the product being shipped, the more expensive a flat rate box becomes. The heavier the product, the better deal is the flat rate box.
The last issue I have with USPS boxes is they don’t always present well. End load cartons require the product be stuffed into a small opening at either end. Our die cut boxes open as presentation boxes with an attached, hinged lid allowing the product to be displayed, enhancing the consumers “unboxing experience”.
What is the value of peel and seal and easy open strips on a mailer box?
For people who don’t like to mess with tape and are not eager to cover their graphics with any type of box sealing tape, the value of a peel and seal adhesive strip is substantial. For packers, the time saved can be as much as 20 to 30% per box. That is meaningful whether your own people do the packing and sealing or if you are utilizing a fulfillment operation to package and ship your orders. These boxes tend to be more secure and not as easy to tamper or pilfer the contents.
Of course, if you seal a box that securely, the problem for the recipient is opening it, ideally without a knife or scissors. Our reinforced pull tab (easy open perf) makes opening the box quick and safe.
Send and return, two-way DTC mailer boxes
Another great advantage of a custom box with this type of design is that an additional adhesive strip can be applied to the box, one below and one above the easy open perf. The consumer can open the box and then reuse the same box for a return trip to the shipper. This is great for product returns, exchanges, repairs, etc.
Our Globe Guard® peel and seal mailers have a 1,000 MOQ just like our standard mailers. Though when we quote them, due to costly set up time, you will see a substantial savings at 2,000 or 3,000 boxes. Since they are custom, not stock, virtually any size or style can be made for your specific application but may require a onetime cost for a custom cutting die.
Keep in mind that some of these unique features are also available on our unpadded paper mailers and rigid paperboard mailers. So, if you really don’t need a box, we may have an alternate solution available for you.
You can contact us via www.SalazarPackaging.com or call us at 630-551-1700. Our experienced branded packaging advisors will be glad to help you determine if our peel and seal mailer boxes are a good packaging option for you.
The people at ThreeMain Products realized their DTC packaging requirements were not simple or basic. The packaging they needed for their excellent, eco-friendly cleaning products would have to be flexible and be able to accommodate a variety of different shapes, sizes, and configurations.
After seeing some of our work on our website including our gallery, they knew we were up to the structural packaging design challenge.
Product and Size Appropriate Packaging
Many companies attempting to minimize initial packaging costs will try to develop a “one size fits all” e-commerce shipping container. This typically means oversizing the box which adds to packaging cost, shipping costs and creates more waste. This results in a poor customer presentation (unboxing experience) and excess board used, sure to be noticed by their sustainability-minded consumers.
The ThreeMain Starter Kit
This product is simply three same size, reusable aluminum bottles of their products and three spray nozzles. We created a custom insert to separate the products, preventing bottle to bottle metal abrasion and by making the insert removable, the box can potentially be used for other products or configurations. This design resulted in a minimal size at minimal cost for packaging and shipping.
The ThreeMain Blue Membership Kit
This product combination required more creativity due to the mixture of products being shipped together. For this kit we created a two-level container placing the bagged product on the lower level and protecting it with the upper level supports on the inside corners of the base. The upper level tray included a divider and product separators like what we used on the starter kit above. We added a couple of pull tabs to make removing the upper level easier and of course, we used our eco friendly corrugated material that is 100% recyclable with any paper waste. Our white on Kraft printing provides a nice, natural look to the earth friendly package.
“Eco Consistent” Branding and Packaging
Eco Consistent is a phrase we coined around ten years ago, simply stating that it was important for packaging to reflect and be consistent with the brand owner’s philosophy and approach to market. All too often it is not, but we are glad to say that ThreeMain Productshas successfully accomplished that primary objective.
Are you ready for “packaging that communicates”? You can contact Salazar Packaging via email or call us at 630-551-1700. One of our experienced, green minded branded packaging advisors is ready to help you deliver your products and message.
Packaging Options for DTC (D2C) intimate apparel and swimwear
Many people know us as the company that created the beautiful packaging for Sophia Vergara’s EBYpanty subscription program, but our experience in that product arena goes well beyond that project. Over the many years we have specialized in custom printed packaging for e-commerce, we have been asked to create eye catching and cost-effective packaging for many new and up-and-coming product lines of intimate apparel including lingerie, bras, panties, and swimwear. The types of packaging commonly used are eco-friendly paper, unpadded mailer envelopes, rigid mailer envelopes and of course, corrugated DTC (D2C) shipping boxes.
Unpadded paper mailers
The fact is that most clothing products do not require padding, yet many people ask us for bubble lined envelopes for their apparel items. We have two major problems with that: according to most consumers, a padded, bubble lined plastic mailer envelope is NOT eco-friendly, and the padding adds cost unnecessarily because the products being shipped are not fragile or breakable.
Our unpadded paper mailers are a customer favorite because they can be as much as 100% recycled content, easily recycled (curb side for most), available custom printed in small quantities, available in white or Kraft as well as flat or gusseted.
Unpadded rigid mailer envelopes
Rigid mailers are typically used for products that you want to protect from bending or creasing in shipment. Photos and documents are a good example of most common rigid mailer applications. However, for the sake of presentation and keeping the clothing flat rather than crumpled up or wrinkled, a flat or gusseted custom size, custom printed mailer might be the best option.
Corrugated mailer boxes
With a low 1,000 MOQ, these can be custom printed inside and out. Add a little tissue in a solid color or matching branded print and your customers will have an exceptional (department store like) unboxing experience. There has never been a better time to use corrugated boxes. The equipment has become more versatile and efficient and the raw material corrugated board has more options available than ever before. Different finishes, different print processes, and unique board structures. For example, the triple white board we have promoted for medical, cosmetic, and other applications where overall box appearance is important.
Focus on right sizing
Since clothing does not really require undesirable void fill, shipping your product in the smallest possible container is the key even if it means utilizing a variety of designs, materials, and sizes. For example, the EBY project shown in the photo required three different mailer box sizes and one rigid paperboard mailer envelope size. This not only minimized packaging costs, it also helped reduce mailing costs while making a better presentation.
Packaging we don’t recommend for clothing
High on the list of my personal packaging pet peeves are poly mailers. As someone who spent a good part of my packaging career selling plastic packaging, I can tell you that the materials used are almost identical to the film structure of a good quality garbage bag – copolymers, multi-layer structures, etc. However, if you really want to ship your apparel in something that resembles a Hefty garbage bag and can accept the high MOQ for custom printing poly mailers (25,000), this may be a viable option. The plastic material issue of that option must be acceptable to you, your customers, and consistent with your brand.
The other item on my “do not use” list is any form of poly/paper combination. These are used extensively in their unattractive manila yellow color by overseas shippers. Both materials individually may have some sustainable merit but when laminated together, neither material is recyclable and will undoubtedly end up in a land fill.
Ready to serve you
Every clothing and apparel application and customer is different, for example, the solution we would recommend for a low volume producer of organic cotton baby clothes may be different than what we suggest for a large volume producer of a very expensive, lacey bra and panty set.
Our branded packaging advisors are experienced and will be glad to answer any questions you may have about your specific application. You can or call us at 630-551-1700. We also invite you to visit our gallery where you will see a small sampling of our work.