Custom Corrugated Boxes

Custom Corrugated Boxes Engineered to Your Specification

Custom corrugated boxes let you match board grade, flute and print to the exact product rather than forcing goods into a stock size. Getting the construction right first protects margins, reduces damage in transit and lifts the quality of every unboxing. Because Packlic builds each carton to order, you specify only the strength, style and branding your product actually needs, which keeps board cost, freight weight and wastage all under tight control.

Flute and Wall Construction Explained

Flute profile sets the wall thickness and the way the board cushions and prints. B flute at around 3mm gives a firm, flat surface ideal for crisp graphics and resists board collapse under load. C flute near 4mm adds stacking height and shock absorption, which suits slightly bulkier goods, while E flute at around 1.5mm produces a thin, rigid wall for compact retail cartons with fine detail. F flute is finer still for premium small packaging. For heavier or fragile products we combine liners into double wall BC or triple wall, gluing multiple fluted mediums between liners so the box gains far greater rigidity and puncture resistance. Choosing the profile deliberately keeps board cost aligned to the real protection each product needs.

Strength, ECT and Real-World Protection

Board strength is specified by the Edge Crush Test for stacking and the Mullen burst, or bursting, test for puncture resistance. A single wall B or C box near 32 ECT copes with typical courier parcel weights, while double wall grades push well past 44 ECT for palletised stacking and long supply chains. Because ECT correlates closely with box compression strength, matching the rating to your gross weight, stacking pattern and transit distance is what stops cartons crushing at the base of a stack. We factor in warehouse humidity too, since damp air softens fibre and reduces strength, then specify a grade that holds shape through handling, storage and delivery without over-building the box.

• ECT matched to load weight
• Burst rating for puncture resistance
• Grades for courier or freight

Sizing, Styles and FEFCO Options

We manufacture to your internal dimensions so products sit snug without excess void fill, which is one of the quickest ways to cut both damage and cost. The regular slotted container, FEFCO 0201, remains the workhorse, but full-overlap slotted boxes for extra base strength, half-slotted containers with a separate lid, five-panel folders for long items and fully die-cut display styles are all on the table. Custom scoring, tuck flaps, crash-lock bases and self-locking closures can be built in as needed. Tight sizing lowers the dimensional weight carriers bill on, reduces the loose fill you buy, and speeds packing because each product drops into place.

Use Cases Across Retail and Shipping

Because a single tool can carry branded print and genuinely protective board, custom corrugated boxes work equally well for ecommerce fulfilment, subscription kits, wholesale distribution, hamper and gift packaging and retail-ready display. Brands use them to standardise packaging across a whole product range while keeping each SKU correctly sized, which streamlines picking, packing, storage and returns. A consistent, well-fitted carton also protects margin by reducing breakages and the refunds and replacements they trigger. From a single premium product box to a full case-and-tray shipping system, the same custom approach scales across the catalogue.

Printing and Finishing

Print options span economical single-colour flexo for logos and text through to high-resolution litho-laminated CMYK for photographic artwork and gradients. A white top liner sharpens colour and gives clean whites, while kraft delivers a natural, recyclable look that suits eco-led brands. Finishing includes matt or gloss varnish, spot detailing, embossing and precise die-cutting for handles, windows or tear strips. Every design is proofed on a free 3D mockup, and physical samples can follow, so colour, coverage and structure are all approved before the press run begins.

• Flexo, litho or digital print
• Kraft or white top liner
• Matt, gloss or spot varnish

Sustainability and Wholesale Ordering

Corrugated is one of the most widely recycled packaging materials and is made largely from recovered fibre, so right-sizing the board is both a commercial and an environmental win. We help you specify the lightest grade that still passes transit testing, trimming material use and freight emissions without risking damage. Water-based inks, recyclable coatings and single-material construction keep the finished box kerbside recyclable for your customers.

Order custom corrugated boxes wholesale from 100 units, with pricing that improves at volume, fast turnaround and free artwork proofing on every job. Boxes ship flat and glued or stitched at the joint for efficient storage and quick assembly at your packing line.