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RETAIL PACKAGING BOXES Packaging Solutions

Custom Retail Packaging Built for the Shelf

Get custom retail packaging made to fit, protect and present your products properly. Choose your box style, size, material, print and finish, with support from initial specification through to production.

Protects ProductsSecure structure for packing and delivery
SustainableRecyclable and responsible options
High Quality PrintCMYK, Pantone and premium finishes
Strong & ReliableDurable materials for safe delivery
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Excellent customer feedback on Trustpilot
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29+ Packaging
Solutions
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Not sure which packaging is right for you? Our team can help match the structure to your product, brand and budget.
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Custom DimensionsMade to fit your product precisely.
Low Minimum OrderMOQ from 100 units per design.
Printed to Your BrandCMYK, Pantone and specialist finishes.
Fast Turnaround7-10 working days after artwork approval.
Retail Packaging Range

Explore Retail Packaging by Product Style

Browse retail boxes built for shelf display, product protection, launch packaging and clear customer presentation.

Product Group 01

Shelf-Ready Retail Boxes

Printed retail cartons and display formats for products sold in store.

4 products
Product Group 02

Ecommerce & Subscription Boxes

Mailer and fulfilment styles for direct-to-customer retail orders.

4 products
Product Group 03

Presentation & Gift Boxes

Premium structures for branded retail launches and higher-value product ranges.

4 products
Product Group 04

Practical Product Cartons

Strong, cost-effective boxes for everyday retail packing and delivery.

4 products
Product Group 05

Shelf-Ready Retail Boxes

Printed retail cartons and display formats for products sold in store.

4 products
Product Group 06

Ecommerce & Subscription Boxes

Mailer and fulfilment styles for direct-to-customer retail orders.

4 products
Product Group 07

Presentation & Gift Boxes

Premium structures for branded retail launches and higher-value product ranges.

4 products
Product Group 08

Practical Product Cartons

Strong, cost-effective boxes for everyday retail packing and delivery.

1 products
Retail Packaging Planning

Retail Packaging Starts With How You Sell

Retail packaging should be planned around the product, sales channel and selling environment before appearance decisions are made. A box for a shelf, counter, hanging display or ecommerce order may need to perform differently even when the product itself is similar.

01 Protect Keep the product appropriately contained and supported.
02 Present Give the product a clear, organised retail presentation.
03 Inform Provide suitable space for necessary product information.
04 Display Suit the shelf, counter, hanging or other retail position.
05 Handle Work with stocking, customer handling and purchase.
01

Cosmetics & Beauty

Main need
Product presentation and clear variant identification
Initial direction
Plan around product size, shelf position and customer handling
02

Food & Confectionery

Main need
Containment, presentation and suitability for the product
Initial direction
Start with the food format, sales environment and handling needs
03

Electronics & Accessories

Main need
Controlled product positioning and clear retail presentation
Initial direction
Consider weight, components, sales channel and expected handling
04

Health & Personal Care

Main need
Product identification and organised information space
Initial direction
Confirm product dimensions, sales route and information requirements
05

Apparel & Fashion Accessories

Main need
Presentation with suitable space for the product
Initial direction
Consider folding, display method, size and customer interaction
06

Home, Lifestyle & Gifting

Main need
Product support combined with suitable retail presentation
Initial direction
Plan around weight, presentation level and how the product is purchased
In-Store Retail Presentation, stocking and customer handling come first.

The packaging needs to work with the intended retail environment and how shoppers see, handle and purchase the product.

Ecommerce Distribution introduces an additional set of requirements.

Courier handling and transit protection need to be considered separately from the product's retail presentation.

Retail Box Structures

Choose the Right Retail Box Structure

Retail box styles solve different packing, opening, support and display requirements. The right structure should be selected according to how the box needs to assemble, hold the product and perform in the retail environment.

Straight tuck end retail box structure
01

Straight Tuck End

Uses tuck flaps at both ends opening in the same direction, creating a clean folding-carton format with broad printable panels.

Key advantage
Simple assembly with balanced front and back panels
Choose when
A lightweight retail carton needs straightforward opening

Consider: Product weight, tuck depth and required panel orientation.

Reverse tuck end retail box structure
02

Reverse Tuck End

Uses top and bottom tuck flaps that close in opposite directions, allowing an efficient folding-carton layout.

Key advantage
Efficient carton layout with convenient access
Choose when
A compact retail carton needs opposite-end closures

Consider: Artwork orientation and which end should be opened first.

Auto lock bottom retail box structure
03

Auto-Lock Bottom

Uses a pre-glued base that forms as the carton is opened, reducing the manual work needed to close the bottom.

Key advantage
Faster packing with greater base support
Choose when
Packing speed or base strength is more important

Consider: Product weight, board grade and the packing process.

Window retail packaging box structure
04

Window Cartons

Includes a cut-out viewing area so part of the product remains visible without opening the box.

Key advantage
Product visibility while retaining a carton structure
Choose when
Seeing the product supports the buying decision

Consider: Window size, panel strength and the added window material.

Retail box with hanging header tab
05

Hanging & Header-Tab Boxes

Adds a reinforced header or hanging feature so the carton can be presented on hooks or peg-based fixtures.

Key advantage
Supports vertical merchandising without shelf space
Choose when
The product will be displayed from hooks or pegs

Consider: Hanging load, hole position and reinforcement around the header.

Sleeve and tray retail packaging structure
06

Sleeve-and-Tray Boxes

Combines an outer sleeve with an inner tray to create controlled opening and more deliberate product presentation.

Key advantage
Distinct opening format with separate outer branding
Choose when
The opening experience is part of the presentation

Consider: Sliding tolerance, tray depth and product retention.

Display ready retail packaging structure
07

Display-Ready Structures

Uses an open-front, tray or convertible construction so products can remain organised while being presented in-store.

Key advantage
Combines product organisation with merchandising
Choose when
Multiple units need to be presented together

Consider: Unit count, display footprint and stability as stock reduces.

Rigid presentation retail packaging box
08

Rigid Presentation Boxes

Uses a thicker set-up construction where greater rigidity and a more substantial presentation format are required.

Key advantage
Greater rigidity and controlled presentation
Choose when
The product requires a more substantial retail format

Consider: Storage volume, product weight and whether transit protection is separate.

Choose structure according to
01 Packing speed
02 Product weight
03 Opening method
04 Retail position
05 Customer access
Retail Environment

Design Around the Retail Environment

The same product can need a different box depending on where it will sit, how customers handle it and which retail fixture it needs to work with.

Retail Situation Packaging Consideration
Shelf Display

Front-facing area, stacking stability and product visibility.

Hanging Display

Header strength, hanging position and loaded pack weight.

Counter Display

Compact footprint, fast product access and efficient use of limited space.

Peg / Display Hooks

Euro-slot position, header area, tear resistance and loaded weight.

Premium Counter

Surface finish, opening experience and controlled presentation.

High-Volume Shelving

Packing efficiency, consistent dimensions and repeatable shelf presentation.

Structure Decision
01 Shelf position
02 Product orientation
03 Customer handling
04 Retail fixture
05 Box structure
Retailer requirements should be supplied before approval.

Where a retailer provides dimensional, hanging, labelling or packaging specifications, these should be reviewed before the final structure and artwork are signed off.

Retail Packaging Materials

Materials for Retail Packaging

Board choice affects strength, print quality, folding behaviour and how the finished pack performs in-store. Select the material around product weight, structure and handling requirements first, then develop the required surface appearance.

01

Folding Boxboard

Lightweight paperboard suited to printed cartons that need clean folds and efficient retail presentation.

Strength
Light to medium
Print surface
Smooth and print-friendly
Typical application
Cosmetics, food, personal care and small retail products
Consideration
Not intended for heavier loads without structural support
02

Kraft Board

Paper-based board with a natural brown appearance, often used where the material itself forms part of the brand look.

Strength
Light to medium
Print surface
Natural brown surface
Typical application
Natural products, food, gifting and lifestyle retail
Consideration
Colours reproduce differently than on white board
03

Corrugated Board

Fluted board construction used where retail packaging requires additional rigidity, stacking strength or transit support.

Strength
Medium to high
Print surface
Printable outer liner
Typical application
Heavier products, displays and retail-ready packaging
Consideration
Flute grade affects thickness, print and structure
04

Rigid Greyboard

Thick structural board used where a more substantial, premium retail presentation is required.

Strength
High rigidity
Print surface
Usually wrapped with separate printed paper
Typical application
Luxury retail, gift sets and premium products
Consideration
Core board and visible wrap are separate specifications
05

Specialist & Premium Papers

Decorative papers can change colour, texture and tactile presentation without necessarily providing the main structural strength.

Strength
Depends on underlying board
Print surface
Textured, coloured or specialist finish
Typical application
Premium retail, gifting and branded presentation
Consideration
Check print, foil, adhesive and wrapping compatibility
Structure vs Surface The visible material and the structural board are not always the same.

A rigid retail box may use greyboard for strength and a separate printed paper wrap for colour, branding and texture. These should be specified independently.

Need to compare board types in more detail?

Review the main packaging materials and their structural applications before confirming the retail box specification.

Explore Packaging Materials
Print & Finish Planning

Printing & Finishing for Retail Shelves

Print and finish choices affect more than appearance. They influence colour consistency, surface character, tactility, highlighted details and how the pack handles everyday retail use.

01

Printing

Choose the print method around artwork, colour requirements, substrate and production volume.

Colour & Reproduction

CMYK

Four-colour process printing suited to detailed graphics, photography, gradients and artwork containing many colours.

Best for Full-colour artwork

Pantone / Spot Colours

Specified spot colours can be useful when particular brand colours require tighter control than a standard process build.

Best for Brand colour consistency

Digital Printing

Useful for suitable shorter runs, prototypes and applications where conventional plate-based production may not be required.

Best for Suitable short-run work
02

Finishing

Finishes can change sheen, texture, tactile response, emphasis and surface protection.

Surface & Detail

Matte / Gloss

Changes surface sheen and the visual character of printed artwork.

Surface appearance

Foil

Adds metallic or contrasting detail to selected logos, lettering or graphic elements.

Highlighting

Emboss / Deboss

Raises or recesses selected areas to introduce physical depth and tactile detail.

Tactility

Spot UV

Creates targeted gloss contrast over selected printed areas rather than the entire surface.

Visual emphasis

Specialist Papers & Coatings

Introduce texture, colour or functional surface properties depending on the selected material and coating.

Texture & durability
What Are You Trying to Change? Match the production choice to the required shelf result.
01 Colour consistency

Print process and colour specification

02 Surface appearance

Board, paper, matte or gloss treatment

03 Tactility

Embossing, debossing and textured papers

04 Highlighting

Foil, Spot UV and selective details

05 Durability

Suitable coatings and surface treatments

Planning a Critical Brand Colour?

Understand how process and spot colour approaches differ before approving artwork for production.

Pantone vs CMYK Guide Finishes & Add-ons
Functional Packaging Features

Windows, Inserts & Retail Features

Retail packaging features should solve a specific requirement: showing the product, holding it securely, fitting a retail fixture or making the pack easier to open, carry and use.

01

Die-Cut Windows

Product visibility

Creates an open viewing area so shoppers can see or sometimes touch part of the product without opening the carton.

Check

Window position, remaining panel strength, product alignment and exposed-product protection.

02

Window Films

Protected visibility

Adds a transparent film behind a cut-out where product visibility is required with a covered viewing area.

Check

Film specification, adhesion area, required clarity and how the additional material affects end-of-life options.

03

Paperboard Inserts

Product positioning

Helps position products consistently, separate components and reduce unwanted movement inside the outer box.

Check

Product dimensions, removal experience, board thickness, tolerances and movement during handling.

04

Dividers

Product separation

Separates multiple products or components to organise sets and limit direct contact between individual items.

Check

Compartment dimensions, product movement, divider height, board grade and packing sequence.

05

Product-Retaining Tabs

Movement control

Uses cut and folded areas of board to locate or retain a product without requiring a completely separate insert.

Check

Product geometry, insertion pressure, removal, board strength and whether the tabs can mark the product.

06

Hanging Headers

Hanging display

Extends the carton above the product area to provide space for hanging and additional front-facing communication.

Check

Loaded weight, header depth, board strength, hanging position and available retail fixture space.

07

Euro Slots

Hook merchandising

Provides a shaped hanging slot for presenting suitable packaged products on retail hooks or peg displays.

Check

Slot dimensions, loaded weight, board strength, product balance and the retailer's fixture specification.

08

Carry Handles

Handling convenience

Integrates a carrying point into suitable larger retail packs, gift sets and multi-product cartons.

Check

Packed weight, handle reinforcement, board tear resistance, balance and carrying comfort.

09

Tear Strips

Controlled opening

Creates a defined opening route where quicker or more controlled first access is required.

Check

Tear direction, board behaviour, strip position, opening force and whether the box needs to remain usable afterwards.

10

Internal Printing

Inside-box communication

Extends branding, instructions or product information onto internal panels that become visible during opening.

Check

Artwork orientation, visible panels, print process, fold positions and areas covered after assembly.

Feature Planning Start with the requirement, not the add-on.
01 Product Size & weight
02 Retail Use Shelf, hook or counter
03 Requirement Show, hold or open
04 Feature Specify & engineer
Retail vs Ecommerce

Retail Display vs Ecommerce Delivery

Packaging designed for shelf presentation does not automatically provide the protection needed for fulfilment and courier distribution. The complete packed system should match the product's actual journey.

01
Retail Presentation

Designed for the Shelf

Retail packaging is primarily planned around merchandising, customer handling and clear product communication.

Focus Shelf presentation
Handling Customer & staff interaction
Structure Product fit & merchandising
Priority Visibility & communication
02
Ecommerce Distribution

Designed for the Journey

Ecommerce packaging must additionally account for handling, movement, stacking and parcel distribution conditions.

Focus Distribution protection
Handling Fulfilment & courier networks
Structure Impact & compression resistance
Priority Movement control & protection
Complete Packed System The retail carton may be only one part of the delivery solution.

Suitable corrugated mailer constructions can sometimes combine presentation and distribution functions. Lightweight folding cartons and premium presentation boxes may need a separate protective outer carton.

Retail Carton Only
Product Retail Carton Shelf
Retail Carton + Transit Protection
Product Retail Carton Outer Carton Courier
Can one box do both? Sometimes — if the structure is designed for both presentation and distribution.

Corrugated retail-ready or mailer-style packaging can sometimes serve both functions. The decision depends on product weight, board grade, internal movement and the expected distribution journey.

Sustainable Retail Packaging

Sustainable Retail Packaging Decisions

Sustainable retail packaging is not defined by one material. Board choice, pack size, inserts, coatings and added components all influence material use and end-of-life options.

01

Recyclable Paperboard

Suitable paperboard constructions can support straightforward recycling routes where added components remain compatible.

02

FSC® Board Options

FSC®-certified board options can support responsible sourcing where the selected material and supply chain are covered.

03

Recycled Fibre Options

Recycled-content boards can be considered where structural, print and presentation requirements remain suitable.

04

Kraft Boards

Kraft can provide a natural paper-based direction for retail cartons, sleeves and other folding structures.

05

Right-Sizing

Reducing unnecessary pack volume can lower material use and avoid excessive empty space.

06

Paper-Based Inserts

Paperboard or corrugated inserts can provide product positioning while reducing reliance on some plastic internals.

07

Reduced-Plastic Design

Windows, inserts and closures can be reviewed to identify where plastic components are genuinely required.

08

Material Reduction

Remove unnecessary layers, oversized panels and decorative components that do not provide a clear function.

Complete Construction Check

Paper-Based Does Not Always Mean Mono-Material

Retail packs often combine board with other components. These should be reviewed together before making recyclability or material claims about the finished packaging.

W Windows

Film or clear panels can introduce another material.

L Laminates

Surface films can change the finished construction.

C Coatings

Barrier or decorative coatings should be considered.

F Foils

Metallic details add another material or treatment.

A Adhesives

Glue type and coverage are part of the complete specification.

I Mixed Inserts

Foam or plastic inserts can alter end-of-life options.

01 Choose suitable board
02 Right-size the structure
03 Review added components
04 Assess finished construction
Need to review wider sustainability options?

Explore material sourcing, recyclability and packaging design considerations before confirming the retail specification.

Explore Sustainability
Production Support

Why Businesses Use Healey for Retail Packaging

Effective retail packaging comes from planning product fit, structure, material, artwork and production requirements as one specification rather than treating each stage separately.

Retail packaging sample, dieline and material swatches under review
Pre-Production Review Structure, artwork and materials checked together.

Reviewing the assembled sample alongside the dieline, artwork and material specification helps identify issues before the production run is approved.

01

Structure & Sizing

Box construction and dimensions are planned around product weight, fit, retail use and packing method.

02

Material Selection

Board grade and surface material are matched to the required strength, print and presentation.

03

Insert Development

Inserts, dividers and retaining features can be developed around the actual product dimensions.

04

Dieline Support

Production layouts account for panels, folds, closures, glue areas and final dimensions.

05

Artwork Checks

Panel orientation, bleed, safe areas and print positioning are checked against the final structure.

06

Sampling

Physical samples help assess product fit, assembly, opening, presentation and structural behaviour.

07

Print & Finish Planning

Print method, colour requirements and finishes are considered before production artwork is approved.

08

Production Planning

The approved specification is translated into a manufacturable retail packaging format.

09

Repeat-Order Consistency

Approved dimensions, board and print positioning provide the reference for future production runs.

Need help developing the complete specification?

Packaging design support can bring structure, sizing, inserts, artwork and production requirements together.

Packaging Design Services
Project Flow
01 Specify
02 Design
03 Sample
04 Produce
05 Repeat

Recent Packaging Projects

Real packaging work produced for customer brands.

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How Your Packaging Is Produced

1

Requirements

Share product size, quantity, use case and artwork status.

2

Structural Planning

The right size, board and box style are reviewed.

3

Artwork and Proofing

A digital proof is prepared before production begins.

4

Production

Boxes are printed, cut, folded and finished to specification.

5

Quality Control

Finished packaging is checked for structure and print quality.

6

Delivery

Completed packaging is packed and delivered to your business.

What Customers Say

We have been using Healey for years and are always impressed by the service, quality and speed.

Harry George

The packaging is of high quality, strong cardboard. I will definitely be using them again.

Amanda Newman

Great communication, quick and good product. I really recommend.

JOON Plant Based Atelier

Frequently Asked Questions

Retail packaging is the packaging customers see and handle when a product is sold in-store or through a retail channel. It can protect the product, communicate branding and product information, support shelf presentation and make the product easier to identify. Custom retail packaging is normally developed around the product dimensions, weight and intended selling environment.

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Tell us your product, target look, and how you ship. We'll recommend the right board, print, and finish for performance.

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