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Custom Packaging 101: What First Time Buyers Should Know

Custom Packaging

Blog – June 2025

If you’re exploring custom packaging for the first time, the process can feel overwhelming. However, the right partner can simplify the process and help you create packaging that protects your product, showcases your brand, and leaves a lasting impression. Here’s what you need to know to get started.

What Is Custom Packaging and Why Do You Need It?

Custom packaging refers to packaging that’s been specifically designed and produced for your product and brand. It’s a smart choice if you’ve outgrown stock boxes, need better protection, or want to elevate your branding and customer’s unboxing experience.

You’ll typically choose between two options:

1. Custom Printed Stock Packaging

This option utilizes a standard box customized with your logo, colors, and messaging. If your product does well in a standard package but you want to elevate your brand, semi-custom packaging is a great option. It’s a budget-friendly, entry-level way to make your package pop while keeping the structure simple.

2. Fully Custom Packaging

If your product is fragile, uniquely shaped, or premium, full-custom packaging allows you to control the dimensions, structure, inserts, materials, and artwork. While this option costs more upfront, it often reduces waste, lowers shipping costs, and strengthens your brand presence.

Packaging Lingo to Speak Like a Pro

Use these key terms to navigate conversations with your packaging partner:

  • Dieline – A flat layout that shows how your packaging will be cut, folded, and printed.
  • Flute – The wave-shaped layer in corrugated cardboard that adds strength. Boxes come in different board grades based on several factors, including flute type.
  • Insert – Custom interior supports that protect your product inside the box.
  • MOQ – Minimum order quantity.
  • Spot UV, foil, and embossing – Decorative techniques that add shine, texture, or dimension.
  • Tooling – The custom molds or equipment used to create your packaging’s shape and features.

Want more terms? Check out our full glossary.

What to Expect from Your Packaging Partner

When you work with American Box Company, you gain more than a vendor; you gain a partner that’s invested in your product’s success. As a full-service packaging partner, we provide:

  • Structural design
  • Graphic design
  • In-house prototypes
  • Onsite manufacturing
  • Fulfillment
  • Vendor-managed inventory

We don’t believe in one-size-fits-all solutions. We get to know your customer base, your budget, and your goals. Then, we design a unique packaging solution tailored to fit your product.

The Custom Packaging Process

Timelines vary based on your specific needs, but starting early generally yields the best results. The design process can often take 6 to 12 weeks. Production typically takes 7 to 10 days, with longer processing times if tooling is required.

1. Consultation and Estimate

Start with a free consultation. A member of our creative team will discuss your product, packaging needs, design preferences, and budget with you. Your consultation will go more smoothly if you know:

  • Your product’s size and weight
  • Whether your product will be shipped one at a time (UPS/FedEx) or in a pallet load
  • If you need a retail package or shipping package only
  • Desired look and feel
  • Quantity estimates and budget

It’s okay if you don’t have all of these answers. We’ll help you narrow down your choices and then provide a detailed quote.

2. Design and Dieline Creation

Our designers will use your input to create a packaging concept tailored to your brand and product. Once you approve the brand, we’ll create a dieline, a technical layout that shows precisely how your packaging will be cut, folded, and printed.

3. Prototype

American Box Company will produce a physical sample so you can see and test your packaging.

4. Production

Once you approve the dieline and prototype, the project will move into full production.

5. Delivery

After a quality check, your packaging is shipped to your location. If you need storage, we can warehouse your packaging inventory for you.

Mistakes to Avoid

Many first time buyers make similar mistakes. Knowing what to watch out for makes them easier to avoid.

1. Miscalculating Product Dimensions

Measure your product precisely to prevent small errors that can cause big problems.

2. Skipping the Sample Stage

You may think you’re saving time or money, but skipping the sample stage can lead to costly mistakes.

3. Starting Too Late

Not allowing enough lead time from when you start your project to when the final product is needed can limit your options and may result in rush fees.

4. Prioritizing Form Over Function

Your packaging needs to protect your product and ship well, not just look good. Our team will help you find the right balance.

5. Holding Back Questions

We love to talk packaging! Ask us anything. It’s what we’re here for.

Ready to Get Started?

Your packaging is more than a box; it’s your brand’s first impression. With custom packaging, you can create a box that showcases and protects your product while leaving a lasting impression on your customer.

Contact us today to see how American Box can help you bring your packaging vision to life.

Looking for packaging inspiration? Explore our gallery for some of the solutions we’ve created for other businesses like yours.

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