Custom Packaging Solutions
When standard sizes won't work, we design and build custom corrugated packaging engineered to your exact specifications — using sustainable materials whenever possible.
What We Can Build for You
From simple dimension adjustments to fully engineered packaging systems, our custom solutions cover every corrugated need.
Custom-Sized Boxes
Standard sizes don't fit everything. We manufacture boxes to your exact specifications — any length, width, and height combination with the right wall strength for your products.
- Any dimension combination
- Single or double wall
- RSC, HSC, or die-cut styles
- Minimum order from 100 units
Modified Gaylords
Need a gaylord with a drop-front panel? Extra height? Reinforced bottom? We modify standard gaylord designs to match your warehouse workflow and product requirements.
- Drop-front access panels
- Custom height options
- Reinforced corners & bottoms
- Integrated pallet bases
Specialty Liners
Protect your products with custom-fit liners — from moisture barriers for food-grade applications to anti-static liners for electronics and foam-lined solutions for fragile goods.
- Poly moisture barriers
- Anti-static liners
- Foam inserts & cushioning
- Temperature-insulated liners
Kitting & Assembly
We assemble multi-component packaging systems so they arrive ready to use. Pre-folded boxes with liners installed, dividers in place, and labels applied — straight to your line.
- Pre-assembled packaging
- Divider installation
- Label application
- Shrink-wrap bundles
Our Custom Process
Needs Assessment
We start with a detailed consultation to understand your product dimensions, weight requirements, shipping conditions, and volume needs. Our packaging engineers analyze every variable.
Design & Engineering
Our team designs your custom packaging using CAD software, considering structural integrity, material efficiency, and sustainability. We optimize flute type, wall construction, and closure method.
Prototyping
Before full production, we create physical prototypes for you to test. Load-test, drop-test, and fit-check your products to ensure the design meets every requirement.
Production
Once approved, we produce your custom boxes using recycled materials wherever possible. Quality control checks at every stage ensure consistency across your entire order.
Delivery & Support
We deliver on schedule with our own fleet, and provide ongoing support for reorders, design modifications, and seasonal volume adjustments.
Industries We Serve
Custom packaging solutions tailored for every sector.
Detailed Material Options
Corrugated packaging performance starts with material selection. Understanding flute types, liner grades, and coatings ensures your custom box is engineered for its specific application.
Flute Types
| Flute | Height (mm) | Flutes per Foot | Best For |
|---|---|---|---|
| A Flute | 4.8 | 33-36 | Maximum cushioning. Ideal for fragile goods, glass, and delicate electronics. Provides the best stacking strength. |
| B Flute | 3.2 | 47-52 | Good crush resistance with a smoother printing surface. Popular for die-cut retail packaging and canned goods. |
| C Flute | 3.6 | 39-43 | The most common flute worldwide. Balanced stacking strength, cushioning, and printing quality. Our default recommendation. |
| E Flute | 1.6 | 90-98 | Thin-profile corrugated for primary retail packaging. Excellent print surface, light weight. Used for pizza boxes, shoe boxes. |
| BC Double Wall | 6.4 | — | Two layers of fluting bonded together. Heavy-duty applications: industrial parts, heavy machinery components, double-stacked pallets. |
Liner Grades
The liner is the flat paper bonded to each side of the corrugated fluting. Liner grade determines surface quality, printability, and moisture resistance.
- Kraft Liner (26-42 lb)
Standard brown kraft. Economical, strong, recyclable. The workhorse liner for shipping boxes.
- Test Liner (23-33 lb)
Made from recycled fiber. Lower cost, slightly lower burst strength. Ideal for non-structural applications.
- White Top Liner
Bleached or clay-coated surface for high-quality printing. Used when the box is the product presentation.
- Mottled White Liner
Partially bleached kraft with a white printing surface. Cost-effective compromise between kraft and full white.
Coatings & Treatments
Coatings add specialized properties to corrugated packaging — moisture resistance, grease barriers, anti-corrosion protection, and more.
- Wax Curtain Coating
Fully saturated wax treatment for waterproof applications. Used in produce, seafood, and meat packaging.
- Wax Cascade Coating
Surface wax application that provides moisture resistance without full saturation. More recyclable than curtain coating.
- Poly Coating (PE Lamination)
Thin polyethylene film bonded to the liner. Creates a moisture and grease barrier for food-contact packaging.
- VCI (Vapor Corrosion Inhibitor)
Chemical treatment that releases anti-corrosion vapors. Protects metal parts during storage and shipping.
Minimum Orders & Lead Times
Lead times depend on complexity, material availability, and quantity. Here is what to expect for typical custom packaging projects.
| Project Type | Min. Order | Prototype | Production | Total Lead Time |
|---|---|---|---|---|
| Custom-sized RSC (plain) | 100 units | 2-3 days | 5-7 days | 7-10 business days |
| Custom RSC with 1-2 color print | 500 units | 3-5 days | 10-14 days | 13-19 business days |
| Die-cut box (custom shape) | 250 units | 5-7 days | 10-14 days | 15-21 business days |
| Full-color printed box | 100 units | 3-5 days | 7-10 days | 10-15 business days |
| Modified gaylord container | 25 units | 3-5 days | 7-10 days | 10-15 business days |
| Multi-component kitting system | 50 units | 7-10 days | 14-21 days | 21-31 business days |
| Specialty coated packaging | 500 units | 5-7 days | 14-21 days | 19-28 business days |
Lead times are estimates. Rush orders may be available for an additional fee. Reorders of previously produced designs ship faster since tooling is already in place.
Custom Packaging Case Studies
These are real projects we have engineered and delivered for customers across the New York metro area. Names are anonymized for client confidentiality.
Artisan Candle Brand — Subscription Box
Challenge
A Brooklyn-based candle company needed a custom mailer box that could safely ship 3 glass candles per month to subscribers. The box needed to reflect their premium brand aesthetic with a clean white exterior and branded interior printing.
Solution
We designed a die-cut E-flute box with custom foam inserts to cradle each candle. White-top liner with full-color interior printing. The box included a perforated tear strip for easy opening and a magnetic closure for reusability.
Auto Parts Distributor — Heavy-Duty Gaylord
Challenge
A Long Island auto parts distributor was losing product to moisture damage in non-climate-controlled warehouse bays. Standard gaylord boxes deteriorated within weeks of outdoor storage, and contents were exposed to rain and humidity.
Solution
We engineered a modified 5-wall gaylord with wax cascade coating on all exterior surfaces and a PE-laminated inner liner. Added reinforced double-wall bottom with integrated pallet base for forklift handling. Drop-front panel for warehouse accessibility.
Organic Farm — Produce Shipping Boxes
Challenge
An upstate NY organic farm shipping CSA (Community Supported Agriculture) boxes to NYC needed food-grade packaging that was ventilated for produce freshness, sturdy enough for stacking 3-high in delivery vans, and visually branded.
Solution
We designed a custom RSC with die-cut ventilation holes on all four sides, 2-color flexo printing with the farm logo and handling instructions, and B-flute construction for crush resistance. Wax cascade coating on the bottom panel for moisture from produce.
Electronics Manufacturer — Anti-Static Shipping
Challenge
A New Jersey electronics manufacturer needed packaging for sensitive circuit boards and components. Requirements included anti-static protection, precise interior fitment to prevent movement, and the ability to stack palletized boxes 4-high in a shipping container.
Solution
We designed a custom RSC with anti-static treated liner, die-cut corrugated interior partitions to hold each component in place, and ECT-rated (Edge Crush Test) walls for calculated stacking strength. Each partition cell was sized to the exact component dimensions.
Design File Requirements
If you are providing your own artwork for custom-printed boxes, here is what we need to ensure the best possible print quality and fastest turnaround.
Our design team can also create artwork from scratch or adapt your existing brand assets to corrugated print specifications. This service is included free of charge for orders over 1,000 units.
File Specifications
- File FormatAdobe Illustrator (.ai), PDF/X-1a, or high-res EPS. Avoid JPG, PNG, or Word files.
- Resolution300 DPI minimum for raster images. Vector artwork preferred for logos and text.
- Color ModeCMYK for full-color printing. Pantone (PMS) spot colors for flexo printing.
- Bleed AreaExtend all graphics 0.125 inches beyond the trim line on all sides.
- Font HandlingConvert all text to outlines/curves. Do not embed fonts.
- Dieline TemplateWe provide a dieline template for your designer to place artwork. Contact us for your specific box dimensions.
Prototyping Timeline
Our prototyping process is designed to catch design issues before committing to full production — saving you time and money.
CAD Design
Our engineers create a 3D CAD model of your custom box based on your specifications. You receive a digital proof with dimensions, material callouts, and fold lines.
Sample Cutting
We cut a physical prototype on our sample table using the exact material specified for production. No die required — the sample is cut with a digital plotter.
Fit Testing
We ship the prototype to you for fit testing with your actual product. You check dimensions, closure, stacking, and overall look and feel.
Revision (if needed)
Based on your feedback, we adjust the design and cut a revised prototype. Most projects require zero to one revision before production approval.
Quality Testing Standards
Every custom packaging design is validated against industry-standard performance tests to ensure it meets your functional requirements.
Edge Crush Test (ECT)
Measures the edgewise compressive strength of the corrugated board. ECT rating determines how much stacking weight a box can bear. We test to TAPPI T 811 standards and specify ECT ratings (23, 29, 32, 40, 44, 48, or 51 ECT) based on your stacking requirements.
23-51 ECT availableBurst Test (Mullen)
Measures the force required to puncture the corrugated board. The Mullen burst test (TAPPI T 810) is the traditional strength measure and is still specified by many freight carriers. We test finished boxes and provide burst strength certificates on request.
125-350 lb burstDrop Test (ISTA)
Simulates the impacts a package experiences during shipping. We perform ISTA 1A, 2A, and 3A series tests depending on your distribution environment. Each test involves controlled drops from specified heights onto corners, edges, and flat surfaces.
ISTA 1A/2A/3ACompression Test (BCT)
Measures the maximum compressive load a finished box can sustain. Box Compression Test results predict real-world stacking performance accounting for box dimensions, not just board strength. Critical for warehouse stacking calculations.
Per McKee formulaMoisture Resistance
For wax-coated and poly-laminated boxes, we test moisture vapor transmission rate (MVTR) and direct water exposure resistance. Cobb test (TAPPI T 441) measures water absorption of the board surface over a defined period.
Cobb value specifiedPrint Quality
Color consistency, registration accuracy, and barcode readability are verified on printed boxes. We use spectrophotometer readings to confirm Pantone color matches and barcode verification equipment to ensure scan-first-time rates meet GS1 standards.
Delta E < 3.0Sustainable Custom Packaging
Custom packaging does not have to mean wasteful packaging. In fact, custom-engineered boxes often use less material than standard sizes because they are precisely sized to the product — eliminating excess void fill, reducing shipping weight, and lowering dimensional weight charges.
We prioritize recycled-content corrugated stock for all custom projects. Our standard recommendation is 50-70% post-consumer recycled content, with options up to 100% recycled fiber for applications where maximum recycled content is a priority. All our custom boxes are 100% curbside recyclable.
For customers with corporate sustainability reporting requirements, we provide material certificates documenting recycled content percentages, fiber sourcing, FSC or SFI chain-of-custody certification, and estimated carbon footprint per unit.
Recycled content available in custom corrugated stock
Typical material reduction vs. using oversized standard boxes
Curbside recyclability of all our custom corrugated packaging
Chain-of-custody certification available on request
Frequently Asked Questions
What is the minimum order quantity for custom boxes?
Our minimums vary by project type: 100 units for plain custom-sized RSC boxes, 250 for die-cut designs, and 500 for flexo-printed boxes. Digital printing allows minimums as low as 100 printed boxes. Modified gaylord containers start at just 25 units due to the hand-assembly involved.
How much does custom packaging cost compared to standard boxes?
Custom boxes typically cost 20-50% more per unit than standard sizes at comparable quantities. However, right-sized custom packaging often reduces total packaging cost by eliminating void fill, reducing DIM weight shipping charges, and lowering damage rates. Many customers find that their total cost-per-shipment actually decreases with custom packaging.
Can I order a sample before committing to a full production run?
Absolutely. We produce 1-3 physical prototypes for every custom project before full production. Prototypes are produced on the same material specified for the production run. Sample charges range from $50-$200 depending on complexity, and are credited back to your production order.
What if my product changes and I need to modify the box design?
Design modifications are common and expected. If the change is minor (small dimensional adjustment, text change on printing), we can usually update the existing die or plate at minimal cost. Major redesigns may require new tooling, but we retain your CAD files and specifications indefinitely, making future changes faster and cheaper.
Do you offer storage and release programs for custom boxes?
Yes. For customers who need to order in bulk for economies of scale but lack warehouse space, we offer inventory management programs. We produce your full order, store it in our facility, and release quantities as needed on a call-off basis. Storage fees are minimal and often offset by the per-unit savings of larger production runs.
Can custom boxes be made from 100% recycled materials?
Yes. We can source corrugated board made from 100% recycled fiber for most custom applications. However, 100% recycled board has slightly lower burst and stacking strength compared to virgin fiber, so we may recommend a heavier flute profile to maintain performance. We will advise you on the best material choice that balances sustainability goals with functional requirements.
How do I get started with a custom packaging project?
Contact us via our website form, email, or phone. Provide as much detail as you can about your product dimensions, weight, quantity needs, and any special requirements (printing, coatings, food-grade compliance). Our engineering team will schedule a free consultation, typically within 24 hours, and begin the design process.
Have a Unique Packaging Challenge?
Our engineering team loves solving custom problems. Share your requirements and we'll design a solution that fits perfectly — and sustainably.
Start Your Custom ProjectHow to Evaluate Packaging Products Like an Operations Team
A product catalog is useful, but the real purchasing decision usually depends on fit-for-use. The right question is not just whether a box exists in the correct size. The better question is whether that box matches your load, handling method, storage duration, customer expectation, and total landed cost.
Commercial buyers often save the most when they separate needs into categories: customer-facing shipments, internal transfers, warehouse storage, low-volume odd sizes, and seasonal peaks. Once those categories are defined, it becomes much easier to decide where used boxes make sense and where new production is justified.
This product library is designed to support that kind of decision-making. Each category has a different strength profile, cost structure, and operational use case, and the best results come from matching those details to your actual workflow rather than defaulting to one box style for everything.
Before choosing a product category, confirm
- Required dimensions, usable interior fit, and pallet compatibility
- Whether appearance, print quality, or food-contact compliance requires new material
- Expected weight, stacking load, and handling conditions in storage and transit
- Whether accessories such as liners, caps, tape, or edge protectors should be specified at the same time
Related Reading
Additional guides and articles that deepen the topic on this page.