What Are the Main Cost Drivers?
Every box price is built from a handful of parts. The board and the size decide how much material each box uses. The print decides the set-up and ink. The quantity decides how widely the set-up is shared. Everything else is a refinement.
| Factor | Effect on price | How to save |
|---|---|---|
| Size | More board per box as size grows | Fit the box closely to the product |
| Board grade | Double wall uses about twice the paper | Use the lightest grade that protects |
| Print colours | Each colour adds set-up and ink | Use 1 or 2 strong colours |
| Print coverage | Large solid areas use more ink | Keep designs open and simple |
| Inside print | Adds a second print pass | Print only the panels that matter |
| Quantity | Set-up shared across more boxes | Order in fewer, larger runs |
Why Is Size the First Thing to Get Right?
A box that is 20 mm too large on every side uses noticeably more board, needs more void fill and may cost more to post. Fitting the box to the product saves on all three at once. If you only change one thing about your packaging, make it the size. Our measuring guide for inside sizes shows how.
How Much Does the Board Grade Add?
Board is priced roughly by the amount of paper in it. Double wall BC flute has two flutes and three liners, so it costs more than single wall of the same size. E flute is thinner than B or C, but the difference in price between single wall grades is smaller than the jump to double wall. Choose the grade for the load, not out of caution.
What Does Print Really Cost?
Print has two parts: a set-up for each colour and the running cost of ink on each box. On small runs, the set-up dominates, so a 1 colour logo on 250 boxes adds more per box than the same logo on 2,500 boxes. Full colour uses a different process with its own set-up, and it is best on white board.
- Plain: no print set-up at all
- 1 colour: one set-up, the most economical branding
- 2 colour: a set-up for each of two inks, logo plus a second colour
- Full colour: photos and patterns, priced on coverage
Is Inside Print Worth It?
It depends on how your box is used. For mailers that customers open at home, the inside lid is often the most valuable panel: it is seen at the moment of opening. For trade cartons that go straight to a warehouse, inside print adds cost with little benefit. A common compromise is a simple logo outside and a pattern or message inside.
How Does Quantity Change the Price?
Set-up costs are fixed per run, so they are spread more thinly as quantity rises. That is why the price per box falls with larger orders, quickly at first and then more gently. If you order the same box several times a year, combining those orders into one run usually brings the price down.
How Do You Compare Options Fairly?
Seeing options side by side on one quote is the easiest way to judge whether print or a heavier board is worth the difference for your business.
- Fix the size first, because it affects everything else.
- Ask for plain and 1 colour prices on the same quote.
- Add a second board grade if you are unsure about strength.
- Compare two quantities to see how the price per box moves.
- Consider storage space before ordering a very large run.
Where Can You Save Without Cutting Corners?
None of these weakens the box or makes it look cheap. They simply put the money where it shows.
- Use kraft board with one dark colour instead of full colour
- Print one or two panels rather than all of them
- Choose B flute rather than double wall for light parcels
- Standardise on fewer box sizes and order more of each
- Use printed tape or labels on plain boxes for small runs
Does Print Add to the Lead Time?
Only by the proof stage. Plain boxes go straight into production once the order is confirmed. Printed boxes need a proof, which we usually send with the quote or soon after; once you approve it, production takes the same 4 to 6 working days. If you are in a hurry, approving the proof quickly is the best way to keep things moving.
When Is Printing Not Worth It?
For boxes that only ever travel between businesses, such as stock moving between a supplier and a warehouse, print rarely pays for itself. The same applies to boxes that go inside an outer carton, where nobody sees them until the outer is opened. In those cases, plain board and a printed label do the job at the lowest cost.
Should You Lock In a Larger Run?
Only if you have the space and the design is settled. A bigger run lowers the price per box, but boxes take room even when flat, and a change of logo or size halfway through leaves stock you cannot use. Many buyers settle on a run that covers two or three months of orders.
What Does a Box Start From?
Our boxes start from £0.20 a box for compact, plain single wall cartons in good quantities. The exact figure for your box, with every option priced, comes by email within one working day of sending the size and quantity.