A Step-by-Step Guide to Creating a Custom Corrugated Box at Royal Containers
Custom corrugated boxes offer a multitude of benefits for businesses, including enhanced branding, improved product protection, and efficient packaging solutions. Designing and creating a custom corrugated box may seem like a daunting task, but with the team at Royal Containers, we can bring your packaging vision to life. In this blog, we will provide you with a step-by-step guide on how we create a custom corrugated box that perfectly fits your unique needs.
Step 1: Define Your Products Packaging Needs
The first step in creating a custom corrugated box is to clearly define your requirements. With the help of our knowledgeable sales team, we will determine the appropriate packaging solution based on the size, shape, budget, and weight of your products. We will also take this time to discuss any special features or additional packaging elements you may need.
Step 2: Choose the Right Corrugated Board
Selecting the appropriate corrugated board is crucial to ensure the durability and strength of your custom box. Together, we will review factors such as the level of protection required for your product, the transportation conditions it will face, and any environmental considerations. Consulting with our team also means determining the right flute combination (eg. single wall, double wall, or triple wall) for your specific application.
Step 3: Design the Box Structure
Now it’s time to design the structure of your custom corrugated box. The potential for creating diverse structural and visual designs for corrugated boxes is virtually limitless. At Royal, our job is not done until we have explored all the available choices with the brand owners, suppliers, retailers, and key decision-makers.
Our options are endless and carefully tailored to match the exact specifications of your product. Our sales professionals consistently advise clients to consider a 3D rendering and/or sample of the concept before proceeding with production, ensuring client approval. During the sample stage, it is common to encounter minor sizing adjustments. With the continuous evolution of the industry, the utilization of AI (Artificial Intelligence) is becoming increasingly prevalent. This technology enables packaging suppliers to demonstrate to brand owners how their products will appear on store shelves, enhancing visibility and marketability.
Step 4: Incorporate Branding and Graphics
One of the advantages of custom corrugated boxes is the ability to showcase your brand identity and create a memorable unboxing experience. With our dedicated team of graphic and design specialists, we take pride in our “Imagineering” approach to our work, embracing creativity alongside our valued customers. We can incorporate your company logo, colours, and other branding elements into the box design. We offer boxes either plain or printed, catering to your specific needs.
At our facility, we offer the following types of printing:
- Flexographic Printing
Flexographic printing involves the use of a plate to transfer your graphics and text onto substrates. These flexible plates, made of raised rubber or plastic, depict the desired artwork. Mounted on cylinders, the plates receive direct ink application on the raised areas. Next, the packaging substrate passes through the machine, transferring the image onto the packaging material. - Digital Printing
Digital printing employs laser or inkjet technology to directly print a digital image onto the substrate. As plates are not required, this process is faster than direct flexo printing and offers high customization options. It can produce vivid colours and is well-suited for creating intricate images and design elements such as smooth gradients and shadows. - Label Printing and Application
Alternatively, you can print your design on a label and then affix it to the final packaging. This approach is commonly used to achieve distinctive finishes on corrugated packaging, such as soft touch or glossy boxes.
Step 5: Manufacturing and Production
Once you are satisfied with the design and structural integrity, it’s time to proceed with manufacturing and production. At Royal Containers, we have made significant investments in state-of-the-art machinery, enabling us to efficiently fulfill orders with utmost speed and precision.
From a simple brown box to an eye-catching retail display, our production process breathes life into creative design. In today’s fast-paced world, time holds greater value than money. Therefore, finding the right packaging for your brand and budget promptly is our top priority.
These five steps to creating a custom box are not just integral to our identity, but they also exemplify why Royal remains a leader in our industry. Contact the knowledgeable team at Royal Containers to learn more about how we can achieve your packaging goals.
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