Custom Packaging Solutions
When off-the-shelf won't work, we design and deliver packaging tailored to your exact requirements. Custom sizing, private labeling, kitting, design consultation, and volume programs — all backed by local, hands-on service from our Boise team.
Start Your Custom Project
Describe your packaging challenge and we'll get back to you with ideas and a preliminary quote within one business day. The more detail you provide, the more accurate our initial recommendation will be.
Custom Sizing
Standard box sizes do not fit every product. Over-sized boxes waste space, increase dimensional weight shipping charges, and require more void fill. Under-sized boxes risk product damage and customer dissatisfaction. Custom sizing eliminates both problems.
Our Process
Share your product dimensions and weight, and we will calculate the optimal internal box dimensions, recommend the right board grade, and produce samples for your approval before manufacturing.
What's Included
- +Precise internal dimensions matched to your product with optimal clearance for cushioning materials
- +Available in single-wall, double-wall, and triple-wall corrugated with your choice of flute type
- +RSC (Regular Slotted Container), HSC (Half Slotted Container), FOL (Full Overlap), and telescoping styles
- +Minimum order as low as 50 units for standard custom sizes; die-cut designs may require 250+ units
- +Prototyping available — we will send you physical samples before you commit to a full production run
Private Labeling
Your boxes are the first physical touchpoint your customers have with your brand. Private labeling turns a plain brown box into a branded experience that reinforces your identity, communicates professionalism, and creates a memorable unboxing moment.
Our Process
Provide your artwork files (AI, PDF, or high-resolution PNG/JPG) and we will prepare press-ready proofs for your review. We handle registration, trapping, and color separation to ensure your print is clean and accurate.
What's Included
- +Single-color flexographic printing for high-volume runs — most cost-effective option for simple logos and text
- +Multi-color flexographic printing (up to 4 colors) for detailed branding with pantone-matched inks
- +Digital printing for short runs (50-500 units) with full-color, photographic-quality graphics — no plate charges
- +Lithographic lamination for premium retail packaging requiring the highest print quality
- +Interior printing available for unboxing experiences — surprise messaging, instructions, or brand stories inside the box
Kitting Services
Kitting is the process of assembling multiple components into a single, ready-to-ship package. Instead of ordering boxes, liners, dividers, tape, and labels separately and assembling them in your facility, we pre-assemble everything into kits that your team can use immediately.
Our Process
Tell us what components go into each kit, the assembly sequence, and your expected volume. We will set up a kitting operation, produce sample kits for your approval, and maintain inventory for ongoing orders.
What's Included
- +Box + liner + divider + cushioning assembled as a single unit — grab, fill, close, ship
- +Pre-taped boxes with one end sealed, ready for single-hand filling on packing lines
- +Multi-component product kits combining different box sizes, accessories, and packing materials into one SKU
- +Subscription box assembly with seasonal or rotating components, branded tissue, and inserts
- +Custom labeling applied to each kit for inventory tracking, part identification, or shipping
Packaging Design Consultation
Packaging design is not just about choosing a box size. It encompasses material selection, structural engineering, cushioning design, regulatory compliance, supply chain optimization, and cost analysis. Our consultation service helps you make informed decisions across all these dimensions.
Our Process
We begin with a detailed questionnaire about your product, shipping methods, damage history, and goals. From there, we develop a packaging recommendation with material specs, structural drawings, and cost analysis.
What's Included
- +Product vulnerability analysis — identifying fragile points, orientation requirements, and damage risk factors
- +Material selection guidance — choosing the right board grade, flute type, and liner weight for your application
- +Cushioning design — foam, corrugated, or air pillow systems engineered to protect your specific product
- +Regulatory review — ensuring compliance with ISTA, ASTM, UN/DOT hazmat, and food-contact regulations
- +Cost optimization — right-sizing materials to eliminate over-engineering without compromising protection
- +Sustainability assessment — identifying opportunities to reduce material usage, switch to recycled content, or implement reuse programs
Sample Development
Before committing to a production run, you need to test your packaging with real products in real shipping conditions. Our sample development process gives you physical prototypes for fit checks, drop testing, and stakeholder review.
Our Process
Once the design is finalized on paper, we cut and assemble physical samples using the same board grades and print methods planned for production. You test them, we adjust as needed, and production begins only after your written approval.
What's Included
- +Hand-made prototype samples from production-grade materials — not just mockups
- +Multiple iterations included — we refine the design until it fits your product perfectly
- +Fit check samples shipped to your facility for hands-on evaluation by your team
- +Optional ISTA-protocol drop testing and vibration testing for performance validation
- +Final production sample approval before full manufacturing begins
Volume Programs
For businesses with predictable, recurring packaging needs, our volume programs offer guaranteed pricing, reserved inventory, scheduled deliveries, and dedicated account management. Volume programs reduce your per-unit costs and eliminate supply uncertainty.
Our Process
We start with a usage analysis of your current packaging consumption across all SKUs. From there, we build a volume program proposal with tiered pricing, delivery schedules, and service level commitments.
What's Included
- +Guaranteed pricing locked for 6 or 12 months — no surprise increases mid-contract
- +Reserved inventory held in our warehouse for your exclusive use, ensuring availability
- +Scheduled deliveries on your timeline — weekly, bi-weekly, or monthly shipments to your facility
- +Blanket purchase orders with flexible release schedules — order once, receive over time
- +Dedicated account manager as your single point of contact for orders, issues, and optimization
- +Quarterly business reviews to analyze usage patterns, identify savings, and adjust quantities
How Custom Projects Work
From initial concept to ongoing supply, our custom packaging process is designed to be collaborative, transparent, and efficient.
Discovery
You tell us about your product, packaging challenges, and goals. We ask the right questions to understand the full picture.
Recommendation
We develop a detailed packaging recommendation covering materials, dimensions, construction, and pricing options.
Prototyping
Physical samples are produced for your review and testing. We refine until the design meets your exact specifications.
Production
Upon approval, we manufacture your custom packaging. First-run quality checks ensure everything matches the approved sample.
Delivery & Support
Your packaging is delivered on schedule. Ongoing support includes reorders, design updates, and optimization as your needs evolve.
Who Benefits from Custom Solutions?
Custom packaging is not just for large enterprises. Any business with a specific packaging challenge can benefit from a tailored approach.
E-Commerce Brands
Right-sized boxes reduce dimensional weight charges, lower void fill costs, and create branded unboxing experiences that drive customer loyalty and social media sharing.
Manufacturers
Custom packaging engineered for your specific parts eliminates damage in transit, reduces packing time on the production line, and standardizes your shipping process.
Food & Beverage
Custom insulated, wax-coated, or ventilated boxes designed for your product specifications ensure freshness, compliance, and brand consistency on retail shelves.
Subscription Services
Branded subscription boxes with custom inserts, tissue, and messaging create the unboxing experience that differentiates your service and reduces churn.
High-Value Products
Electronics, medical devices, and luxury goods demand precision-engineered packaging with custom foam inserts, tamper-evident features, and premium print quality.
Volume Shippers
Businesses shipping 1,000+ boxes per month benefit from volume programs that lock pricing, guarantee supply, and include dedicated account management.
Custom vs. Standard: When to Upgrade
Custom packaging is not always necessary. Here is a practical guide to help you decide when standard boxes will do and when custom is worth the investment.
| Scenario | Standard Boxes | Custom Solution |
|---|---|---|
| Product fits common sizes | Best choice — lower cost, immediate availability | Not needed |
| Unique product dimensions | Requires excessive void fill | Right-sized box eliminates waste |
| Brand presentation matters | Generic appearance | Private labeled, branded experience |
| High damage rates | May lack proper protection | Engineered cushioning and structure |
| Low volume (<50/month) | Most cost-effective | Higher per-unit cost may not justify |
| High volume (1,000+/month) | Works, but misses savings | Volume program locks pricing and supply |
| Regulatory requirements | May not meet specs | Designed to comply from the start |
Our Standard Product Lines
Before going custom, check if our standard products meet your needs. Many businesses find what they need in our existing inventory.
Have a Packaging Challenge?
Whether you need a one-off custom box or a full-scale volume program, our team at 805 S 17th St in Boise is ready to help. No project is too small or too complex.