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Custom Flap Boxes

Custom flap boxes are all of those occasions that demand their very own identity. Each box measures 6″ x 4″ x 2″, and is beautifully crafted with premium materials. They can be personalised with your logo or design to make them very unique. The premium quality paperboard is laminated in matte or gloss finished. It provides two options such as magnetic or ribbon closure. They have a wall thickness of 1.5mm, a base thickness of 3mm, and a durable paperboard weight of 1200gsm.

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Why Choose Healey Packaging?

Premium printing, sustainable materials, fast turnaround, and reliable UK-wide service.

High Quality Printing

Sharp details, rich colours, premium print results.

No Minimum Order

Order from just 100 boxes — ideal for small runs.

Custom Sizes & Styles

Perfect tailored fit — at no extra design cost.

Eco-Friendly Materials

Recyclable, biodegradable, and FSC-certified.

Fast Turnaround

Quick production + reliable delivery times.

Free UK Shipping

Standard orders ship free across the UK.

Types of Custom Flap Boxes

Custom Inserts and Dividers

Templates and dividers are instruments for organising and securing the products. Mostly they are made from foam, cardboard, or molded materials. Foam inserts are recommended for delicate items, such as jewelry or electronics.

They serve as a snug fit against damage. Eco-friendly, versatile, and cost-effective, Cusom cardboard boxes are appropriate for food packaging, cosmetics. Specifically molded inserts provide a perfect fit for luxuries like perfumes or watches.

Window Cut-Outs

Windows are usually made from rigid or cardboard materials. The acetate-cut to enable customers to view the product displayed in retail packaging. The features allow visibility of the product without opening the box. Bakery boxes, toy-packaged items, or beauty products usually contain windows made of paper. They intrigue while safely keeping the product.

Reinforced corners and moisture-resistant coatings improve durability. These features protect fragile or perishable items. They are helpful for businesses shipping internationally or handling heavy products.

Special Finishes

Custom boxes usually incorporate many attractive features like spot UV and embossing. Spot UV spotlights the area for contrast. Embossing gives an appearance of texture and is the same for debossing. it gives these premium touches to the box. It’s glimmeringly done to suit luxurious items such as chocolates or wine. All these features add to an elegant touch in the making of the box.

Customisation

Names, monograms, or over-another messages turn a standard box into an ornate keepsake. Personalised boxes are gaining popularity during weddings, birthdays, and among corporate flaps. High printing technology has made it easier to get marvelous designs that make every box unique and special.

Material Options Custom flap Boxes

Material Types

Kraft paper, corrugated board, and rigid board are some of the materials used for making custom flap boxes.
It is ideal for storing small and handmade products. Corrugated board, on the other hand, is stipulated for bulky products, providing cushioning to heavy items. It is rigid and often makes perfect for luxury packaging.

Comparison of Materials

Kraft Paper: Lightweight and environment friendly. Good for organic or handmade products. Fitting into a green branding scheme.

Corrugated Board: Long-lasting and especially good for shipping heavy items. A good functional option.

Rigid Board: Strong and eye pleasing. Commonly used for premium packaging that raises the value of the product.

Occasions for Custom flap Boxes

Specific Designs For Holiday

flap and custom boxes for holidays are essential ingredients in the making of every season special. For instance, Christmas boxes are not limited to snowflakes, reindeer, and red and green themes. But it brings festive cheer along with them. Valentine’s Day packaging usually includes hearts, flowers, and shades of red or pink. One campaign that comes to mind is Coca-Cola’s Christmas flap packs.

Their red boxes with Santa Claus themes have become the trademark of Christmas holidays. Also, beauty brands such as Lush produce flap sets reminiscent of the particular season but contain scents that are not yet available in their catalogue. This motivates shoppers and increases the value of their items.

Solutions for Retail and E-Commerce

Seasonal packaging is most frequently used by retail and e-commerce houses. Limited-edition holiday boxes from companies like Starbucks quickly create such buzz.

They’re inevitable every year along with their red holiday cups and matching packaging. This custom also goes to e-commerce platforms. During Christmas, Amazon also graces its boxes with holiday greetings and themed visuals. This not only makes the boxes offer product protection but also further enhances the experience of unboxing.

Holiday-Specific Designs

Custom packaging for holidays such as Christmas or Valentine’s Day. It helps to create a festive mood. Seasonal patterns, colours, and graphics bring excitement into the packaging. Christmas boxes are usually decorated with snowflakes and reindeer. Valentine’s Day boxes contain things like hearts and romantic-themed images.

Retail and Event Applications

Retail Packaging

Customisation of flap boxes is a powerful tool for retail branding. A package with a logo or tagline creates for the consumers an identification towards that specific brand. Bright colours with odd shapes usually capture attention on a shelf.

‘Dotcom Distribution’ study states that around 40% of the consumers would more likely share an image of the product if it came in unusual packaging. Thus, this indicates how packaging thoughtfulness leads consumers towards buying something.

Merchandise for Events

Custom boxes develop events, from concerts to expos, as keep-sakes. The boxes keep the items safe and make them reminders of the event. Event packaging brands items. They may quickly turn into collectable items for the audience.

Printing Techniques and Customisation Options

Printing Techniques

1. Digital Printing.

Digital printing is an economical method for a few quantities. There is vibrant colour and crisp detail. This technology works perfectly for personalised or seasonal packaging.

2. Offset Printing.

Offset printing is best used for large quantities for a consistent quality high-definition print. For intricate graphics in retail packaging, it is used.

3. Screen Printing.

Screen printing durability applies with regard to bold designs. These are used for textures, for example, matte or glossy surfaces, and application-oriented benefits of this process also improve the purpose and aesthetics.

Get Personalised Flap Boxes With Healey Packaging

Are you in search of unique and unforgettable flap boxes? Healey Packaging is your answer! We have a large variety of options. Our team is above all else when it comes to packaging solutions. Our expertise in personalisation and special finishes is impeccable. Contact Us at https://healeypackaging.co.uk/.

Dimension (L + W + H) All Custom Sizes & Shapes
Quantities No Minimum Order Required
Paper Stock 210gsm, 250gsm, 280gsm, 300gsm, 350gsm, 420gsm, 460gsm, 500gsm,
Bleach Card (SBS), Eco-Friendly Kraft, E-flute Corrugated, Bux Board, etc.
Printing No Printing, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors
Finishing Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV,
Spot UV, Embossing, Foiling
Included Options Die Cutting, Gluing, Scoring, Perforation
Additional Options Eco-Friendly, Recycled Boxes, Biodegradable
Proof Flat View, 3D Mock-up, Physical Sampling (On request)
Turnaround 7 – 10 Business Days, RUSH
Shipping FLAT

Explore Our Premium Packaging Options

Mix and match materials, printing methods, inks, finishes, and add-ons to build packaging that feels completely on-brand. Start with the material, then move through print and finishing to see what fits your product best.

Strong Corrugated cardboard sheets

Corrugated Cardboard

Shipping • E-commerce • Heavy items

Fluted middle layer for strength and cushioning. Ideal for mailer boxes, shipper cartons, and any product that needs extra protection during delivery.

DurableProtective
Eco Natural brown kraft board

Natural Brown Kraft

Eco brands • Food • Lifestyle

Rustic, uncoated look that feels honest and sustainable. Great for bakery, subscription boxes, and earthy lifestyle brands that want a natural tone.

RecyclableOrganic feel
Premium White SBS bleach card

SBS / Bleach Card

Beauty • Pharma • Retail

Bright white, smooth surface for sharp printing and rich colors. Perfect for cosmetic cartons, medicine boxes, and premium retail packaging.

High print qualityClean white
Luxury Black kraft packaging board

Black Kraft / Black Card

Luxury • Gifts • Apparel

Deep matte black stock that pairs beautifully with metallic foil. Best for luxury rigid boxes, apparel packaging, and special gift sets.

Premium lookFoil-ready
Flexible Digital printing press

Digital Print

Short runs • Variable data

Great for smaller quantities, seasonal packaging, or designs that change often. Fast setup with strong color output and no plate costs.

Low MOQFast
Classic Offset printing rollers

Offset Print

Larger runs • Brand colors

Industry standard for high-volume packaging. Ideal when you need consistent Pantone colors and the most economical cost per unit at scale.

Sharp detailCost-effective
Spot effects Scodix enhancement print

Scodix Enhancement

Tactile • Raised effects

Digital enhancement that adds raised UV, textures, and metallic-style effects to selected areas, creating a premium, touchable finish.

3D feelHighlight details
Gloss UV print on packaging

UV Print

High gloss • Rich color

Cured with UV light for instant drying and strong color density. Works well when you need vibrant prints on coated boards.

ShinyDurable
Standard CMYK ink cans

CMYK Process Inks

Full color • Gradients

Ideal for photography, gradients, and detailed artwork. Most packaging projects start here before adding special colors or finishes.

Full colorVersatile
Branding Pantone ink swatches

Pantone Spot Inks

Exact brand tones

Used when color accuracy is critical. Pantone inks lock in signature brand colors across different print runs and materials.

ConsistentOn-brand
Bold Screen printing ink layers

Screen Printing

Thick ink • Bold coverage

Screen printing lays down a thicker layer of ink, creating vibrant solid colors and strong opacity. Best for bold logos, solid shapes, and designs that must pop even on darker materials.

OpaqueVibrant
Eco Eco friendly vegetable inks

Soy / Vegetable Inks

Eco packaging

Lower-VOC options that support more sustainable packaging. Often paired with kraft stocks and minimalist designs.

Low VOCEco-minded
Matte Matte laminated box

Matte Lamination

Soft touch • Low glare

Gives packaging a smooth, elegant feel with reduced shine. A favourite for luxury, cosmetic, and tech products.

PremiumModern
Gloss Gloss laminated packaging

Gloss Lamination

Shiny • Eye-catching

Adds shine and extra ink protection. Works well for bold colors, retail shelves, and youth-focused brands.

ShinyScuff-resistant
Tactile Soft touch coated box

Soft-Touch Coating

Luxury feel

Creates a velvety, rubberised feel that makes customers want to hold the box longer. Ideal for high-end unboxing experiences.

VelvetyPremium
Highlight Spot UV gloss on box

Spot Gloss UV

Logo & details

High-gloss UV applied only to selected areas like logos or patterns, so they catch the light without making the whole box shiny.

ContrastLogo focus
Luxury Gold foil stamping on packaging

Foil Stamping

Gold • Silver • Custom

Metallic foil pressed into the board for instant shelf impact. Great for logos, borders, and badges on gift, cosmetic, and rigid boxes.

MetallicPremium detail
Raised Embossed packaging surface

Embossing

Raised detail

Embossing lifts selected artwork from the surface, giving logos, patterns, and brand marks a premium 3D raised effect that customers can feel instantly.

3D liftPremium texture
Depth Debossed packaging surface

Debossing

Pressed detail

Debossing presses artwork into the board, forming an elegant recessed impression. Works beautifully for minimalist luxury packaging and fine-detail branding.

IndentedLuxury
Windows Box with die-cut window

Die-Cut Windows

Show the product

Custom window shapes let customers see the product before they buy. Can be left open or backed with clear PET where needed.

RetailProduct focus

Loved by Real Customers

Liz Wheelhouse
★★★★★

“We reached out to Healey Packaging to help us create bespoke shaped boxes… the final product looked amazing and was very well received.”

November 18, 2025
Ash
★★★★★

“Very happy with the service and print quality. Patient with revisions and great communication. A very positive experience.”

September 18, 2025
Vanessa Scott
★★★★★

“The printing quality was excellent and Alex was incredibly helpful. I’ll definitely use Healey Packaging again.”

June 6, 2025
Adrian Tang
★★★★★

“Excellent service, very good quality and sharp printing. Highly satisfied with the results.”

May 7, 2025
G. Mitev
★★★★★

“Our custom boxes arrived exactly how we imagined. Great quality and friendly support from start to finish.”

April 21, 2025
Scott Anthony
★★★★★

“Really great branded hat boxes. Perfectly printed and excellent service. Will definitely return.”

April 14, 2025
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