"It depends" is an unsatisfying answer to the question of what a custom box costs. But it really does depend on a few quite specific things. Once you know them, you can estimate in advance what drives the price up and where you can save without compromising how well your goods are protected.
1. Size: how much board is used
A box is made from a flat blank. The price depends mostly on how many square metres of board the blank takes. In a regular slotted box, the length and the width each appear twice in the blank, and the width is also added to the height because the flaps are made from it.
A 400 × 300 × 200 mm box uses about 0.72 m² of board. Make it 10 cm taller, 400 × 300 × 300 mm, and it needs 0.86 m², roughly a fifth more.
That is why measuring precisely pays off. A box a few centimetres larger than necessary costs more, needs more void fill and takes up more space in the van and on the pallet. The EU Packaging Regulation (PPWR) also limits empty space in transport and e-commerce packaging to a maximum of 50%, so a box made to size is the simplest way to comply.
2. Type of board
Single-wall (3-ply) board is lighter and cheaper. Double-wall (5-ply) board has two flutes, is stronger and costs more per square metre. Within both types there are also different paper grades, which we choose according to the weight of the contents so the box is not over-engineered.
Using weaker board for heavy goods does not pay off, though: one damaged shipment wipes out the savings on the whole batch. We explain how to choose in the article Single-wall or double-wall board?
3. Quantity
Every order requires the machines to be prepared and set up. This work is the same for 100 or 1,000 pieces, so in a larger batch it is spread over more boxes. Larger orders also mean board is bought at a lower price. The price per box therefore falls as the quantity grows.
We make custom boxes from 100 pieces. In our quotation we are happy to price several quantities at once, for example 100, 300 and 1,000 pieces, so you can see when ordering more pays off.
4. Construction: cut or die-cut
Regular slotted boxes, shipping and pallet boxes, layer pads and pallet collars are cut and creased without a special tool. A new size can therefore be made from 100 pieces.
Shaped boxes, such as mailer boxes with locks or unusual flaps, are die-cut. A new shape needs a cutting die to be prepared, so we make them from 300 pieces, and a one-off technical preparation fee is added to the first order.
5. Printing
We print digitally, directly onto the board, without printing plates, from 100 pieces. The price depends on:
- coverage: a small logo, several sides or the whole box
- colours: one colour (black) or full colour
- side: printing on the inside means another pass through the machine
- quantity: the print set-up is spread over a larger batch
Find out more on the Box printing page.
6. Delivery
Smaller orders go by courier, larger ones on pallets or with our own vehicle. Large-format boxes always travel on pallets. The delivery price depends on the weight and the number of pallets. You can also collect your boxes in person in Jablonica.
How to save on your boxes
- Measure precisely. Base the inner dimensions on the product, without unnecessary allowance.
- Standardise sizes. Two boxes can often replace five similar ones, giving you larger batches and a lower price per box.
- Order larger batches at once. You save on set-up and on delivery.
- Choose board according to the contents, not the strongest one "just in case".
- Check our stock sizes. If one fits, you get it faster and from just 25 pieces.
What we need for a quotation
- inner dimensions: length × width × height in mm
- quantity, several options are welcome
- what you will pack and its approximate weight
- single-wall or double-wall board, if you know (otherwise we will recommend it)
- printing: yes or no, coverage and a vector logo
- delivery address
We send a quotation within 48 hours. If you use a different box today, send us its dimensions or a photo and we will compare the price and the specification.
