A custom paper box can be made from several kinds of board, and the board decides how the box looks, how much it protects and how much it costs. Most packaging falls into three families: paperboard for folding cartons, corrugated board for mailers and shipping boxes, and thick greyboard for rigid gift boxes. Each family has its own surface papers and print options.
To browse finished structures, see our custom paper boxes.
Paperboard for folding cartons
Paperboard is a single thick sheet, printed flat and then die-cut, creased and folded. It is the material of tuck end boxes, auto-lock bottom boxes and most retail cartons on the shelf. Common grades include the following.
Solid bleached board (SBS)
SBS is made from bleached pulp all the way through, so it is white on both sides and inside. It gives a bright, smooth surface for full-color printing and a clean white inside when the carton is opened. Cosmetics, skincare and other premium retail cartons often use it.
Coated recycled board (CCNB or grey back)
This board has a white coated printing surface on the outside and a grey recycled back on the inside. It prints well on the outside and usually costs less than SBS. The grey inside shows when the carton is open, so it suits products where the inside is not part of the presentation.
Kraft board
Kraft board is brown and uncoated, with a natural look. Colors print darker on it, so simple one or two color designs work best. Brands that want a plain, natural style often choose kraft for cartons and mailers.
Board thickness is chosen around the product weight and carton size. A larger carton or a heavier product needs thicker board so the panels do not bow. We recommend a grade and thickness in the quotation and you check it on the sample.
Corrugated board for mailers and shipping boxes
Corrugated board has a fluted middle layer between two flat liners. The flutes make it light and stiff, and they absorb knocks in transit. It is the material of mailer boxes and shipping cartons.
Flute size is the main choice. A fine flute such as E-flute gives a thin wall and a smooth surface for printing, and suits small, light products. A larger flute such as B-flute gives a thicker wall for heavier items. The outer liner can be white for brighter print or brown kraft for a natural look. Our mailer box guide covers sizing and board in more detail.
Greyboard for rigid boxes
Rigid boxes such as lid and base boxes, magnetic book boxes, drawer boxes and flip top boxes are built from thick greyboard, also called chipboard. The board is cut and formed into the box shape, then covered with a separate wrapping paper. The greyboard gives the strength and the wrap gives the look.
Because the wrap is separate, you can choose almost any paper for it: printed coated paper, colored or textured specialty paper, or kraft. The wrap is printed and finished before it goes onto the board. Rigid boxes cost more than folding cartons and are usually shipped assembled, but they feel solid in the hand and protect the product better. Read rigid box vs folding carton to compare the two in more detail.
Material comparison
| Material | Used for | Look | Ships |
|---|---|---|---|
| SBS paperboard | Premium folding cartons | White inside and out, bright print | Flat |
| Coated recycled board | Everyday folding cartons | White outside, grey inside | Flat |
| Kraft board | Cartons and mailers with a natural look | Brown, uncoated | Flat |
| Corrugated board | Mailer boxes and shipping boxes | White or kraft liner | Flat |
| Greyboard with wrap | Rigid gift boxes | Depends on the wrap paper | Usually assembled |
Printing and finishing by material
We print by offset printing and can add hot foil stamping, embossing, debossing, UV coating and lamination. White coated surfaces, such as SBS, coated recycled board and coated wrap papers, give the brightest color and take every finish well. On brown kraft, colors look darker and some finishes are less visible, so we review kraft artwork before sampling. See packaging printing and finishing for how each effect works.
Recyclability
Paperboard, corrugated board and greyboard are paper-based. Plastic lamination and some coatings make paper harder to recycle in some systems. If recyclability matters in your market, tell us early, and we can discuss uncoated or lower-coverage finishes and how they change the look.
How to choose
Start with how the box will travel and be seen. A box that sits on a retail shelf usually needs paperboard. A box that goes through the post usually needs corrugated board, or a carton inside a shipping box. A gift box that should feel solid and premium needs greyboard with a wrap. Then choose the surface for the look you want and the print your artwork needs.
If you are not sure, send us the product, its weight and how it will be sold, and we will suggest a material for the sample.
Ordering and what to send
The minimum order is 500 pieces per design. Sampling takes 7 days after the specification is confirmed, and production takes 21 days after sample and artwork approval. Shipping time is quoted separately. To quote, send the product dimensions and weight, the box style or material you have in mind, quantity, artwork and delivery destination through our quote form.