Custom packaging guides

Planning and buying

Before you order: what a quote needs, minimums, lead times, cost drivers, measuring, dielines and the terms on a quote.

How to get a packaging quote that a supplier can actually priceThe eight details a packaging supplier needs to price a box in one pass, what to write if you are unsure, and an example request that prices first time.

What is the minimum order for custom printed boxesWhy packaging suppliers set minimums, why ours starts at 200 units, and what changes between an order of 200 and an order of 1,000 boxes.

How long does custom packaging take, from artwork to delivery, honestlyThree to four weeks from a finished brief to packaging on your dock, and where the days go: dieline, artwork rounds, proof approval, production, transit.

How much do custom boxes cost, and what actually drives the numberBoard, print method, finishes, tooling, quantity and freight set the price of a custom box. What each one does to the number, and how to get a quote fast.

How to measure a product for a custom box, with the clearance that fitsMeasure length, width and height at the widest points, add the right clearance for the box type, and give inside dimensions. The rules we size boxes by.

What is a dieline and how to check yours before you printA dieline is the flat template of your box: cut lines, creases, bleed and safe area. What each line means and the checks to make before you approve one.

Custom packaging glossary100 terms from quotes, dielines and proofs in plain English: boards and flutes, carton and rigid styles, print and finishes, pouch films, labels and ordering.

Mailer and shipping boxes

Corrugated boxes and mailer bags that go to the carrier: board, sizing, rates, returns and breakage.

Mailer box vs shipping box: which one do you actually needMailer box or shipping box? Board, ECT, closure, print and weight compared, with five checks and common shipments to pick the right corrugated box.

Corrugated flutes and ECT: E, B, C and double wall explainedWhat E, B and C flute mean, what 32 and 44 ECT are rated for, and how to pick corrugated board by product weight, print and how the box ships.

White vs kraft mailer box: how to choose for your brandWhite or kraft mailer box? How the liner changes color, scuffing, finishes and recycling, and which suits your artwork. Both from 200 units at Tria.

Subscription box packaging: sizing for the carrier rates that matterHow to size a subscription mailer for the cheaper carrier bands: dimensional weight, cubic tiers, the 18 inch limit and the board that keeps it light.

Packaging for ecommerce returns: what reseals and what to specifyWhich ecommerce packaging survives a return: tuck-lid mailer boxes, second peel and seal strips on mailer bags, tear strips and the label panel, explained.

Poly mailer vs bubble mailer vs rigid mailer: which one to ship inPoly, bubble or rigid mailer? What each protects against, what it costs to ship, and Tria's minimums: poly from 200, bubble from 250, rigid from 500.

How to ship candles safely: the box, the cradle and the heatHow to ship candles without breakage: a cradled E-flute mailer, sizing by jar, inserts for tins and ceramics, summer heat and a simple drop test.

Folding cartons, board and print

Carton styles, paperboard, print methods and finishes.

Straight tuck vs reverse tuck carton: which to chooseStraight tuck cartons keep the front panel clean; reverse tuck cartons pack fast and open from either end. Compared on artwork, weight, packing and board.

Auto lock vs crash lock bottom cartons: which to chooseAuto lock bottoms fold by hand with no glue; crash lock bottoms come glued and pop open. How each works, the 12 oz tuck rule and which fits your packing.

What is SBS paperboard, and 18pt vs 24pt explainedSBS is bleached virgin paperboard with a coated print face. What the point system means, where 18pt stops and 24pt starts, and which one your carton needs.

Digital vs offset printing for boxes: where the line crossesDigital prints without plates and wins on short runs and versions; offset needs plates and wins on volume and spot colors. Where the line crosses.

Foil stamping vs spot UV vs embossing: effect, and which reads as premiumThree finishes compared: what each does to the surface, which boards they need, what tooling they need, and which one reads as premium in the hand.

Soft-touch vs matte vs gloss lamination, side by sideSoft-touch, matte and gloss lamination compared on feel, color, scuffs and fingerprints, which takes foil, and when an aqueous coating is the better call.

Rigid boxes and presentation

Boxes that are kept: how they are built, when they are worth it and how to make the opening count.

Rigid box vs folding carton: feel, cost and when each is the right callRigid box or folding carton? Compare 1200 gsm grayboard with 18pt and 24pt SBS on feel, cost drivers, freight and lead time, and when each one is right.

Rigid box construction: grayboard weight, wrap paper, lid fit and corner typesHow rigid boxes are built: 1000, 1200 and 1500 gsm grayboard, wrap papers, turned-in corners, lid fit tolerance and inner linings, explained.

What is a magnetic closure box, and when it is the right boxA magnetic closure box explained: how it is built, the board and magnets inside, the sizes that work, and when a different rigid box is the better call.

How to design an unboxing experience people filmWhat makes a box worth filming: the reveal order, the inside print, the insert and the sound of the close. What to spend on and what to skip.

Inserts and finishing

What holds the product still and what goes around it.

Packaging inserts: tissue, foam, molded pulp, crinkle filler and ribbon, and what each one is forFoam, molded pulp, paperboard, tissue, crinkle filler and ribbon: what each insert does, which Tria makes, minimums, and how to layer them in a box.

Paperboard insert vs foam insert: which one your product needsPaperboard or foam insert? Which suits light products in cartons and which suits glass and electronics, with Tria's minimums and lead times for each.

Molded pulp vs foam insert: protection, tooling and what you can claimMolded pulp or foam? How each protects, what tooling and minimums apply at Tria, and what you can honestly claim about each. Both from 200 units.

Printed tissue paper: sheet sizes, weight, ink and pattern designHow to size, spec and design custom printed tissue paper: sheet sizes, 17 vs 22 gsm, one or two color flexo and pattern rules. From 200 sheets.

Pouches, bags and tubes

Films, pouch formats, odor and barrier, coffee bags and paper tubes.

Pouch material selection: foil, metallized, clear and kraft filmsHow to choose a pouch film: foil laminate, metallized PET, clear or matte PET/PE and kraft PE compared on barrier, light, odor and windows.

Stand up pouch vs flat bottom pouch: which to chooseStand up or flat bottom pouch? Compare base, stance, printed panels, films, closures and sizes, with the products each suits and common sizing mistakes.

Snack pouch barrier requirements: which film each snack needsWhich barrier film a snack pouch needs: clear PET/PE for dry snacks, metallized for oily nuts, foil for jerky and freeze-dried food. Windows explained too.

Smell proof bags: how odor barriers actually workWhat makes a bag smell proof: a foil layer and closed seals. Foil vs metallized vs clear film, zipper leaks, heat seals, CR zippers and common sizes.

Custom coffee bags: valves, barriers and the sizes a coffee lineup needsCoffee bags explained: why the one-way valve matters, foil vs metallized vs kraft barriers, and the 8, 12, 16 ounce and 2 pound sizes a coffee lineup uses.

Paper tube sizing: inner diameter, wall, length and lidsHow to size a custom paper tube: inner diameter, wall thickness from 0.04 to 0.12 inch and body length, plus slip lids, tin ends and push discs.

What is glassine paper and when you actually need itGlassine is a dense, glazed paper that slows grease and moisture. Where it is used, why we do not sell it, and the cartons and pouches that work better.

Labels

Label stocks, wet and cold bottles, sleeves and the federal label rules.

Product label materials: how to choose the stock, adhesive and finishHow to choose a label stock, adhesive and finish for jars, bottles and boxes, and which Tria build suits each use. Labels from 200 units in 5 to 7 days.

Waterproof bottle labels: the build and the habits that keep them onWhat keeps a bottle label on through condensation, coolers and ice buckets: wet-strength adhesive, lamination and how you apply it. From 200 units.

Shrink sleeve vs pressure-sensitive label: which one your container needsShrink sleeve or flat label? How container shape, coverage, run size and recycling decide it. Tria labels start at 200 units, shrink sleeves at 500.

Beer label compliance: TTB requirements for craft breweriesWhat TTB requires on a beer label, when you need a COLA, the exact health warning and its type size, and which Tria labels survive an ice bath.

FDA Nutrition Facts label requirements: nutrients, type sizes and formatsWhat FDA requires in a Nutrition Facts panel: mandatory nutrients, serving size, type sizes, small package formats and exemptions, citing 21 CFR 101.9.

Food and drink

Bakery, cake, pizza and spirits packaging.

Bakery boxes with windows: sizes, grease resistance and food-contact factsBakery boxes with windows: sizes for cakes, cupcakes, cookies and pastries, how grease resistance works, PET windows and food-contact grade.

Cake box sizing guide: footprint, depth and windowsHow to size a cake box: match the box to the board, add 1 inch over the tallest decoration, and choose depth, window and loading style for each cake size.

Pizza box design: board selection, grease and ventingWhy pizza boxes use B-flute kraft, how vents keep the crust crisp, what to do about grease without PFAS coatings, and the sizes Tria runs from 200 units.

Spirits gift boxes: rigid vs carton, and the compliance notesHow to choose a rigid box or a carton for a 750 ml spirits bottle, how to size it, and what TTB rules mean for the box, from COLA to the health warning.

By product

Complete packaging guides for a single kind of product.

Custom packaging for candles: what holds up in shipping and what looks right on a shelfThe two boxes a candle brand needs: a cradled E-flute shipper and a 20pt auto lock carton for the shelf. Sizes by jar, inserts and warning text.

Custom soap boxes: kraft vs white board, windows and sizingHow to spec a soap box: 18pt kraft or white SBS, PET windows, finishes, how to measure a cured bar and the labeling rules for true soap vs cosmetics.

Skincare packaging: cartons, inserts and the claims you can printThe carton, board and insert for droppers, jars and tubes, the panel every US skincare box must carry, and which claims are cosmetic and which make a drug.

Cosmetics and beauty packaging: cartons, set boxes, labels and the FDA panelCartons, set boxes, mailers and labels for beauty products, what FDA requires on the outer carton, and what Tria does and does not make for cosmetics.

Fragrance packaging: inserts, wraps and the details that sell at the counterFragrance boxes: the insert that holds the bottle upright, the wraps that read as premium, sizes for 30, 50 and 100 ml, and the details buyers notice.

Jewelry boxes: inserts, ribbon and the two sizes a jewelry line needsJewelry boxes explained: the two sizes a jewelry line needs, velvet-flocked inserts for rings, chains and earrings, and ribbon versus magnet closures.

Custom apparel packaging: which box, mailer, bag and tissue to orderWhich box, mailer, bag and tissue to order for apparel, how to size a mailer to a folded garment, and Tria's minimums and lead times for each format.

Supplement and vitamin packaging: cartons, pouches and the label panelCartons, pouches and labels for supplements: which format suits capsules, powders and gummies, what FDA requires on the panel, and the iron rules.

Cannabis, hemp and child resistant packaging

Child resistant closures, state label space and the products that need them.

Child resistant mylar bags: what the rules require and how to stay inside themWhat 16 CFR 1700 child resistance means for a mylar bag: the tested zipper, opaque film, the panel space states require, and the common bag sizes.

CBD packaging compliance: labels, child resistance and the 2026 hemp changeWhat federal and state rules mean for CBD packaging, the December 2026 hemp definition change, and which cartons and CR bags suit tinctures and edibles.

Vape packaging compliance: nicotine warnings, child resistance and the box around the deviceThe nicotine warning rule, child resistance for e-liquid, PACT Act shipping and state cannabis rules, and which Tria vape box or tube fits each product.

Pre-roll tube sizing and compliance: paperboard tubes, CR caps and state rulesHow to size a paperboard pre-roll tube, when it needs a child-resistant cap, and what to confirm with your state regulator before you print.

Gummy packaging: humidity control and child-resistant pouchesHow to keep gummies from sweating, sticking or drying out, and when they need child-resistant packaging, with barrier pouch options and iron rules.

Sustainability claims

Environmental claims you can print and back.

Eco-friendly packaging claims: which ones you can back and how to print themWhich environmental claims hold up on packaging under the FTC Green Guides, what each needs behind it, how to print it, and where California SB 343 stands.

Eco-friendly mailer box claims: what you can print on a corrugated mailerWhich recycling and recycled content claims a corrugated mailer box can carry, what breaks them, and where to print them. Specific to mailer boxes.

Compostable mailer certifications: BPI, OK compost and what you can printBPI, OK compost INDUSTRIAL and OK compost HOME compared, what ASTM D6400 tests, and what the FTC Green Guides let you print on a compostable mailer.