TL;DR (Too Long; Didn’t Read)
🚨 Read This Before You Order Custom Boxes in 2026!
Avoid the biggest (and most expensive) packaging mistakes UK businesses make. This guide reveals what type of box you actually need, which material fits your product, how to avoid sneaky hidden charges, and what red flags to watch for when choosing a supplier. Read now before you place that order.
📦 Bonus: Includes a checklist, sizing tips, and printing breakdown to help you order like a pro.
Why Most Businesses Fail When Ordering Custom Boxes?
Ordering custom packaging seems simple — until it goes wrong. Many UK businesses fall into the same traps: rushing into a bulk order without sampling first, picking the wrong material for their product weight, or being blindsided by extra costs for printing or die-cuts. If you’re planning your first (or next) custom packaging order, this guide will help you avoid expensive mistakes.
Let’s walk through everything you need to know — from box types to material selection, artwork, sizing, and supplier red flags.
Step 1 – Understand What Type of Box You Actually Need
Popular Custom Box Types in the UK
Your product, delivery method, and brand goals determine your box style. Here’s a breakdown of the most common types:
- Mailer Boxes – Great for eCommerce and subscription boxes; self-locking, presentation-friendly.
- Product Boxes – Lightweight cartons for cosmetics, candles, or small goods.
- Shipping Boxes – Corrugated and durable; ideal for bulk or fragile deliveries.
- Rigid Boxes – High-end packaging used for gifts, electronics, or premium items.
- Kraft Boxes – Eco-conscious and rustic; suitable for artisan and food products.
- Eco-Friendly Packaging – Made from recyclable or compostable materials.
- Promotional Boxes – Designed for events, launches, or seasonal gifting.
How to Pick the Right Style Based on Your Product?
- Fragile items? Go for corrugated or rigid boxes with inserts.
- Lightweight retail goods? Product boxes or tuck-flap cartons work well.
- Want a premium experience? Rigid or fully printed mailer boxes are ideal.
Step 2 – Material Mistakes That Cost You Money
Cardboard vs. Corrugated vs. Kraft Material
- Cardboard – Good for retail packaging, but not ideal for shipping.
- Corrugated – Stronger and crush-resistant; ideal for eCommerce and shipping.
- Kraft – Unbleached brown board; eco-friendly and popular in the UK market.
GSM & Flute Guide (Don’t Choose Blindly!)
- GSM (grams per square metre) affects board thickness and durability.
- E-Flute: Fine corrugation; best for printed mailers and retail packaging.
- B-Flute: Thicker and stronger; ideal for shipping heavier items.
- Double Wall: Two layers of corrugation; used for fragile or high-value items.
Step 3 – Order the Correct Size (Box Size Guide)
Getting the wrong size is one of the most common and costly errors.
- Too big and you waste material, pay more for shipping, and risk damage from rattling.
- Too tight and the product may not fit or can get crushed.
✔ Always measure the product’s width, depth, and height.
✔ Account for any protective inserts, padding, or branded cards.
✔ Ask your supplier for help with dieline layout.
Step 4 – Understand Printing Options
Digital, Offset & UV Printing Explained
- Digital Printing – Ideal for low-volume, high-colour designs; fast turnaround.
- Offset Printing – Best for large volumes; gives crisp, consistent print quality.
- UV Printing – Adds durability and allows for glossy, vibrant finishes.
Artwork Requirements Buyers Ignore
- Use CMYK colour mode (not RGB).
- Include 3mm bleed and safe zones in your design file.
- Accepted file formats: AI, PDF, EPS (vector preferred).
⚠ Skipping these steps causes delays or distorted prints.
Step 5 – Hidden Costs No One Talks About
Don’t get caught out. Some of the most expensive mistakes are hidden in the fine print.
- Tooling or Die-Line Charges – Custom shapes or windows can incur setup fees.
- Finishing Costs – Matte/gloss lamination, spot UV, embossing, and foiling all add to the price.
- Delivery Charges – Bulkier boxes or rush orders can rack up shipping fees.
- MOQ Misunderstandings – Minimum order quantity may be higher than you expected.
- Colour Matching Fees – Especially for Pantone or brand-specific colours.
Step 6 – Always Request These Before Ordering
Protect your investment by asking your supplier for:
✔ A free 3D mockup or digital preview
✔ Material proof (especially if you’re testing strength)
✔ Printed colour proof (to verify artwork)
✔ Final all-inclusive quote
Transparency now saves time and money later.
Step 7 – Red Flags When Choosing a Custom Box Supplier
Don’t settle for the cheapest quote without asking key questions. Look out for:
🚩 No reviews or portfolio
🚩 Extremely low prices (often too good to be true)
🚩 Lack of UK warehouse or local support
🚩 Vague lead times
🚩 No design or dieline help
Why Healey Packaging Is a Trusted Custom Box Supplier in UK?
We’ve helped hundreds of UK brands avoid costly packaging mistakes. Here’s what we offer:
✅ Fast turnaround on UK orders
✅ Low MOQs, perfect for small businesses
✅ Free dieline support with every quote
✅ Eco-friendly board options
✅ Full-colour print, foil, embossing and more
✅ 5-star rated by small and large businesses alike
Quick Answers on Ordering Your Custom Packaging
Final Advice – Order Smart, Not Fast
Before ordering, double check:
- You’ve selected the right box type for your product
- You understand the material specs and GSM
- Your artwork is properly formatted
- You’ve accounted for all extra costs
- Your supplier is UK-based and transparent
📦 Need help planning your next packaging order? Talk to our team for tailored advice.
