Rigid boxes are known for their superior product protection and luxurious presentation. However, they come with several drawbacks, including fixed dimensions, increased space requirements, limited flexibility, and potential for damage. These factors contribute to higher costs, making rigid boxes a less ideal choice for businesses prioritizing budget. In this article, we’ll explore cost-effective alternatives to rigid boxes that still provide excellent protection and presentation.
Why Are Rigid Boxes Pricey? Here is Why
- Material: Rigid boxes, also known as set-up boxes, are made from costly chipboard or paperboard that is thicker and heavier than regular cardboard. They require additional paper wraps to cover the solid boards. Because of their built-in qualities, excellent protection, and durability for reuse, rigid boxes are commonly used for luxury packaging, heavier products needing extra support, or when you want to enhance the perceived value of your goods.
- Production: The high cost of rigid boxes is due to extensive equipment set-ups and the significant labor required to wrap and glue them.
- Shipping: Because of the design and construction of rigid boxes, most rigid box styles cannot be compressed or folded, except for collapsible ones. This leads to increased costs due to the handling of heavy, bulky, and non-flat packaging that takes up more space during transportation, often requiring shipment on pallets instead of in multiple packages.
- Storage: The non-collapsible nature of rigid boxes incurs extra costs. They not only require more storage space but also often result in wasted space, potentially increasing warehousing costs.
Alternatives #1 – Corrugated Boxes
Corrugated boxes are a great rigid box alternative if product protection is your priority. Made from fluted materials, they offer outstanding cushioning against impacts during shipping. Corrugated boxes are also more cost-effective to manufacture than rigid boxes. But to get the same look, printability, folding ability and quality as a rigid box, consider the following when customizing your corrugated boxes:
Consider micro-flute type like F or N that has a higher number of flutes per foot
Use thinner, lightweight micro-flute types like F or N, which have a higher number of flutes per foot. This results in a smoother surface, increased stiffness and rigidity, and enables more precise folding operations and direct lithographic (offset) printing. If you’re curious about other available flute sizes, be sure to check out our corrugated master guide.
Choose white coated linerboard for the exquisite outer printing surface
Corrugated cardboard poses challenges when it comes to printing due to its brown color and porous nature, which can make it difficult to achieve the desired print quality. When a high-quality outer printing surface is required, the brown kraft liner on the outer surface can be replaced with a coated white kraft liner. This smooth, white surface is ideal for fine printing and helps prevent ink from bleeding into the porous material, ensuring a crisp and clear printed design.
Use Flexography or Lithographic printing for highest quality print
Flexographic Printing (Direct Printing) is the most popular method used for printing on cardboard boxes. Plates are developed with different designs for each specific color. These plates are then attached to large rotating cylinders that print the designs, one after another—eventually building the complete design. While it has its uses, this type of printing is not recommended for highly intricate designs or photo-quality printing as each color would require a separate plate to be made. But this may work for you if you have simple design with few colors and high volume of materials to justify the creation of plates for flexographic printing.
Lithographic Printing (Offset Printing) is done using litho labels instead of printing directly onto the corrugated board. These labels are first printed with the design and then adhered to the exterior of the linerboard. This method allows high quality, photo-realistic images and intricate design, perfect for brands that want to create a premium look for their packaging. Also, this type of printing gives a smooth and glossy finish that can enhance the overall aesthetic appeal of the packaging, making it a popular choice for consumer goods that need to stand out on the shelf.
Apply a protective water-resistant coating to form a moisture barrier
Applying a water-resistant coating to the corrugated cardboard surface creates a barrier to stop moisture from getting in, the box from getting wet or ink from washing away. This is especially important if you’re packing moisture sensitive products like electronics, food or pharmaceuticals. Having a coated surface also means the printed designs will stay vibrant and legible even in wet conditions. Plus it will extend the shelf life of perishable goods by keeping them dry in transit and storage.
Design die-cut corrugated boxes to precisely fit your product’s dimensions
Corrugated boxes can be designed and die-cut to snugly fit your product’s exact dimensions. This helps eliminate empty space and reduce the risk of your product shifting during transit. With unlimited die cutting customization options, you can also create unique shapes and structures that are not only functional, protective, but also premium. For example, add cut-out handles for easy carrying or transparent windows to showcase the product inside, both functional and visually appealing.
Use box inserts or foam to enhance resistance to heavy loads and stacking pressure and maintain the shape of the contents
To mitigate the downside of corrugated boxes being less resistant to heavy loads and stacking pressure, one effective strategy is to use custom box inserts or foam, which not only bolster resistance to such stresses but also help maintain the shape of the contents. For a more sustainable approach, consider opting for paper-based materials over plastics or foam when creating custom inserts. Additionally, match insert materials with box materials for cost efficiency. Moreover, these extra layers of inserts significantly improve the unboxing experience, adding an element of surprise and delight for the customer while ensuring that the product arrives in pristine condition.
Alternative #2 – Folding Cartons
Folding cartons offer a cost-effective alternative that can still convey quality and achieve a similar look and feel to rigid boxes. They are highly efficient to produce, ideal for automated mass production with minimal retooling, and can be shipped flat to reduce shipping costs. To effectively compete with rigid boxes, leverage the design flexibility and premium finishing techniques available with folding cartons. Keep in mind that folding cartons are constructed from lighter materials and have a more delicate build, so consider the size and weight of your products. Here are some tips to reinforce the structural integrity of folding cartons:
Consider folding carton box styles that are stronger for holding products inside
There are various folding carton box styles, but the snap lock bottom (1-2-3 bottom) and tuck top auto bottom (crash bottom) are among the strongest. The bottom design of both these box styles creates a sturdy base that can hold heavier products compared to other box styles. One advantage of these styles is that they can be shipped flat, with the tabs that require gluing already pre-glued by the manufacturer. This means that upon arrival at your warehouse, all you need to do is assemble the boxes.
When it comes to assembly, both styles are quick and efficient. The snap lock bottom features four flaps that are folded and automatically interlocked to form the bottom in just three steps. Similarly, the tuck top auto bottom can be easily popped open, making the assembly process a breeze.
Use double-layer folding cartons for additional strength and durability
Folding cartons can be made more rigid and sturdy by utilizing a double-layer or double-wall construction, also known as simplex tray boxes. This cost-effective solution is an excellent alternative for heavier products that require the premium look and protection of rigid boxes. The process involves folding a 24 pt board multiple times to create thickness, which adds extra strength and durability to the carton. Additionally, the hollow sides created by the double-layer construction provide stability to the overall structure and contribute to a high-end bulky appearance similar to a rigid box.
Reinforce structure using custom inserts or dividers
Incorporating custom inserts and dividers can provide further structural reinforcement, ensuring products stay secure during transit. These inserts can be crafted from various materials, such as paper-based options, to enhance cost efficiency and eco-friendliness.
Apply premium finishes like embossing, foil stamping, or specialty coatings
Enhancing your folding cartons with premium finishes can significantly elevate the luxurious feel and perceived value of your products. Techniques such as embossing add texture and depth by creating raised or recessed designs on the surface. Foil stamping involves applying a thin layer of metallic or pigmented foil using heat and pressure, resulting in a striking, reflective appearance that catches the eye. Specialty coatings, like varnish, can be used to achieve various finishes, including clear, shiny, matte, or silk, enhancing the carton’s visual appeal. Spot UV coating is another effective technique, applying a glossy, clear coating to specific areas of the carton to create a dynamic contrast between coated and uncoated surfaces. Additionally, lamination involves bonding a thin protective film to the carton’s surface, providing a smooth and durable finish that can be either glossy or matte. These premium finishes not only improve the aesthetic appeal of your packaging but also contribute to a memorable unboxing experience for consumers.
Use Folding Carton for Primary Packaging and Corrugated for Secondary Packaging
Combining folding cartons and corrugated boxes offers a highly efficient and cost-effective packaging solution that maximizes both protection and presentation. Folding cartons are ideal for primary packaging because they are lightweight and can be customised with high end graphics and finishes, perfect for showcasing and shelf display. Meanwhile, corrugated boxes are perfect for secondary packaging, they provide robust protection during transit and storage.
To have a consistent brand image across both packaging types, consider using eco-friendly kraft material for corrugated boxes, which can further emphasize a brand’s commitment to sustainability. A minimalist design with just the logo can achieve a sleek, cohesive look. This combination of folding cartons and corrugated boxes is versatile and can be applied to various industries, from cosmetics to electronics, to meet different packaging needs with style and practicality.
Alternative #3 – Hybrid
Hybrid packaging solutions offer a unique blend of the strengths found in both rigid and flexible packaging options. By combining elements such as corrugated boxes with cardboard sleeves, businesses can achieve a packaging solution that provides the durability and protection of corrugated materials while maintaining the sleek and refined appearance of a rigid box. This approach is particularly suitable for mid-range products that require a balance between cost and presentation, offering a premium look without the high price tag associated with traditional rigid boxes.
Takeaways
Choosing the right packaging solution involves carefully balancing and making trade-offs between cost, protection strength, durability, functionality, aesthetics, assembly difficulty, and storage efficiency. By opting for alternative rigid box solutions like corrugated boxes and folding cartons, businesses can have a similar balance of these factors to rigid boxes but at a more affordable cost.
Be creative when designing your packaging solutions—think outside the box, literally! Try different techniques like premium finishes, printing options, custom inserts, extra packaging accessories and even hybrid or multi-material solutions to turn a plain and boring package into an unforgettable experience for your customer.
For assistance with your packaging project, contact us at https://pakfactory.com/contact-us to design the perfect packaging solution tailored to your needs.
