Ordering custom packaging boxes for the first time? Honestly it goes wrong more than people expect, and it’s rarely dramatic, usually a box half an inch too big or a blue that printed kind of gray. Here are the ones we see every month.
1. Choosing the Wrong Box Size
Size is the big one. Go too big and the carrier bills you for dimensional weight, so you’re basically paying to ship air, and the product slides around and gets dented anyway.
What we tell people is to grab a ruler and measure the real product (the spec sheet is often off by a bit), leave a little room if there’s an insert, and then ask us for the dieline so you can see it flat before anything goes to print.
2. Ignoring Material Quality
If the board is too thin it feels cheap in the hand and it also gets crushed in the truck, so you lose twice. Roughly how we’d match it up:
- Corrugated boxes for anything that ships
- Rigid boxes when it’s a luxury item or a gift
- Kraft product boxes if you want that natural, earthy look
3. Overlooking Printing and Branding
Someone builds the artwork in RGB because that’s what looks right on a screen, then it gets converted to CMYK for the press and the bright teal they loved comes out sort of swampy and they’re upset (fair enough).
We’d set your files up in CMYK from day one, and if one brand color really matters, use a Pantone (PMS) match for it.
4. Not Ordering Samples First
A physical sample costs you a bit up front but it’s how you find out the bottle wobbles in there, or that the foil logo lands right on a fold, while there’s still only one box and not two thousand of them on pallets.
5. Ignoring Minimum Order Quantity (MOQ)
We get why people order 5,000 boxes for a product that hasn’t sold yet, the unit price looks great, but that’s also how a garage ends up full of cardboard nobody needs. Our minimums are low, often around 50 boxes depending on the style, and the price per box drops as you order more, so you can test first and scale later with low MOQ custom packaging boxes in the USA.
6. Not Considering Shipping Costs
Bulky packaging takes a little bite out of every eCommerce order you ship. Double wall corrugated around a lip balm? Overkill, really. Go with the lightest board that still keeps the product safe, and keep the outer box close to the product’s size.
7. Ignoring Eco-Friendly Packaging Trends
Plenty of American shoppers check if a box is recyclable, and a mountain of plastic filler can put them off a brand. Most corrugated and kraft packaging is recyclable, and you can just ask for soy or water based inks.
8. Choosing the Wrong Packaging Supplier
Cheapest quote wins, right? Not always. Check reviews, ask how long production really takes and whether design help is extra. A low price with three rounds of reprints isn’t low anymore.
9. Not Planning for Production Time
For us, standard production is 10 to 12 business days after you approve the proof, then shipping on top of that, not counting artwork back and forth. So if the launch is in three weeks and the art isn’t final yet, you’ve got a problem. Work backwards from your launch date.
10. Ignoring Packaging Compliance and Labeling Requirements (USA Market)
Labels sneak up on people, and a missing one can get a shipment held or a listing pulled off Amazon, which is a pain to sort out. Often left off:
- Basic product information
- A barcode or SKU
- The right warning labels
- Ingredients (cosmetics and CBD especially)
- Recycling symbols
Cosmetic and CBD packaging usually needs clear ingredient and safety info, and we print what you send us, so check the rules for your category before the artwork is final, then make sure the name, ingredients, barcode and warnings are on there.
Why Choose The Pioneer Packaging
We mostly work with small and mid-size brands. Our team sets up the dieline and lays out your artwork for free, checks your files for print problems and sends a digital proof before anything runs, and if you want a physical sample first you just ask. Ground shipping in the USA is free. Have a look around The Pioneer Packaging or send us your size and quantity.
FAQ
Q: What is the biggest mistake when ordering custom packaging boxes?
A: Wrong box size, by a mile, since you pay more to ship or end up with damaged products.
Q: Should I order a sample before bulk custom boxes?
A: Yes, we’d always say so, you get to check fit and print with your own hands first.
Q: How do I choose the best custom packaging supplier in the USA?
A: Compare materials, minimums, real production times and shipping costs, and free design help is a nice bonus if you don’t have a designer.
Keep Reading
Ready to order? Start with eco-friendly packaging, corrugated boxes and rigid boxes. For more background, read avoid these 5 common mistakes when designing custom soap boxes and what information should be printed on candle packaging?.