Smell the Flowers Custom E-Flute Flower Boxes with PVC Window and Gloss Finish
Smell the Flowers needed 1,600 large custom flower boxes that looked premium, stayed sturdy, folded cleanly, and included a shaped front window so the flower product could be seen inside. Healey Packaging recommended E-flute corrugation laminated with 230gsm SBS card instead of 700gsm solid board, helping the customer achieve strength, foldability, gloss presentation, and a clean PVC window finish.
Project Snapshot
The Story
From material concern to 1,600 sturdy flower boxes
Smell the Flowers needed a large premium flower box with strong structure, full-colour artwork, gloss finish, and a front window cut-out. The first concern was material strength: the customer asked about 700gsm board, but that would have made folding difficult and increased the risk of cracking. Healey Packaging guided the customer toward a stronger, foldable E-flute structure, refined the PVC window detail, updated the proof, and moved the approved design into production.
The Challenge
- The box size was large, so the customer needed extra strength and integrity.
- 700gsm solid SBS was considered, but it risked cracking on score lines and tuck flaps.
- The reverse tuck end structure needed to remain foldable and clean after production.
- The artwork included a shaped cut-out area that needed exact placement confirmation.
- The customer wanted a PVC window so the flower inside could be visible.
- A small flap adjustment was needed so the inner tab would not show through the front window.
Our Solution
- Recommended E-flute corrugation laminated with 230gsm SBS card for strength and foldability.
- Explained why the E-flute option was more suitable and cost-effective than 700gsm solid board.
- Prepared and revised digital proofs before production approval.
- Added a clear PVC window to the approved cut-out area.
- Adjusted the inner flap with a small tab cut so it would not appear through the window.
- Produced 1,600 full-colour gloss laminated boxes after final approval.
The Final Boxes
See the Smell the Flowers box in hand
Project Outcomes
Customer approved final result
Our Packaging Process
We review the product, packaging goals, quantities, delivery needs, and brand requirements.
The structure, artwork direction, material choice, and finishing approach are planned around the project needs.
Design proofs and production details are checked before moving into manufacturing.
Approved packaging is produced with the selected board, print method, and finishing options.
Finished packaging is reviewed for structure, print quality, finish, and presentation.
The completed packaging is prepared and delivered for the customer's production or retail workflow.
Materials Used
E-Flute Corrugated Board with SBS Liner
Selected as the strongest and most practical option for a large reverse tuck end flower box. The E-flute structure provided rigidity, while the laminated 230gsm SBS card supported full-colour printing, gloss lamination, and clean folding without the cracking risk of 700gsm solid board.
Printing & Finishing
What Smell the Flowers Said
Amazing service! We've been using Healey for years and we're always blown away by the service, quality and speed of our orders! Adam is always happy to help and is quick to answer any of our queries and even gives great recommendations of what would look best with our packaging. Cannot recommend them enough.
FAQs
700gsm solid board would have been very rigid for this reverse tuck end box and could have caused cracking along fold lines. E-flute corrugation with SBS liner gave the box strength while keeping it foldable.
The boxes were printed in full colour and finished with gloss lamination for a polished retail look.
Yes. A shaped cut-out was confirmed during proofing and finished with a clear PVC window so the flower inside could be visible.
Healey Packaging produced 1,600 custom flower boxes for this project.
Yes. The digital proof was reviewed, the PVC window and flap detail were clarified, and the customer approved the box before printing.
Need food-safe branded boxes like Smell the Flowers?
Share your size, artwork, material, and quantity requirements. Our team will help you choose the right food-safe board, finish, and production route.
- Free Design Support
- No Hidden Charges
- Fast Turnaround
Fourmula Custom Supplement Boxes with Lamination and Holographic Finish
Fourmula needed compact supplement boxes with premium holographic detailing, starting with physical samples before moving into a 1,000-box production order. Healey Packaging…
Read Success Story
Envoplan Furnish Bespoke Event Sweet Boxes
Envoplan Furnish needed a bespoke shaped box to hold sweets for events and client handouts. Healey Packaging helped refine the packaging into…
Read Success Story
JOON Plant Based Atelier Custom Kraft Mailer Boxes with Dividers
JOON Plant Based Atelier needed custom kraft mailer boxes with inner dividers for handmade hot sauce bottles. Healey Packaging produced 200 boxes…
Read Success Story