Why select custom packing materials
A regular box leaves space around the item, allowing it to move about during transport until someone packs the space with foam or paper to keep it still.
Basic packaging with a sticker attached is the simplest option, but it is not designed for anyone in particular.
Custom Pack Studio creates bespoke packaging tailored to your product, ensuring the box, print and finish reinforce your brand rather than overshadowing it.
We make custom boxes, mailer boxes, gift packaging and printed accessories for businesses throughout Abercarn and the valleys beyond, with orders varying from one sample to a complete pallet delivered straight to your warehouse door.
We do not require a minimum order for anything we produce, therefore stock and storage costs are unnecessary until you know a product is going to sell.
Share your packaging specifications, and we will tailor the recommendation to the product.
What custom packaging signifies
With custom packaging, your box is designed around the product from day one, so its dimensions and print fit precisely what you are packing.
Choose the dimensions, enabling a custom-sized box to hold the product securely without unnecessary movement caused by a standard size.
The structure, board weight, print and finish are also individually designed to suit the contents and their journey.
Printing your logo on a stock box creates personalised packaging, involving less work than a fully customisable design.
With customised packaging, every panel, fold and finish can be tailored, even for one run, allowing you to create packaging that fits precisely without any compromise.
Packaging types we offer for Abercarn ventures
We produce a full range of packaging boxes, tailored to custom sizes and printed in full colour using your artwork.
Selecting the right box style and packaging type hinges on your product and how it is handled. Our packaging specialists will guide you through the available options.
Shop cartons and marked packaging
Reverse tuck end cartons remain a standard for retail packaging, ideal for lighter products such as cosmetics and supplements, with flaps that fold in at both the top and bottom.
Crash lock boxes are a sturdier kind of lock box, constructed from cardboard and featuring a base that snaps flat when opened, preventing heavier products from forcing the bottom out.
Shipping and internet shop parcels
A custom-made mailer box safeguards your product throughout the courier network and makes delivery part of the brand experience and visibility, with printing inside and out rather than exclusively across the outer face.
These custom printed boxes are offered with gussets, creating extra depth to keep bigger items securely in place.
Gift boxes, sturdy boxes and roofed boxes
Rigid boxes, gift boxes with magnetic closures and other branded boxes give products bought as presents the polished presentation customers expect, without customers needing to wrap them.
Gable boxes, complete with a handle that folds upwards, are an excellent choice for food gifts and hampers.
For premium lines, we may choose SBS board, solid bleached sulphate and a bright, food safe paperboard, over standard carton stock, while foil and soft touch lamination improve the final effect.
Design assistance for your Abercarn business
Every order includes packaging design support, irrespective of the stage your artwork has reached.
If you have a logo and brand guidelines, our design experts prepare print-ready files and check that the colours remain accurate on board, as packaging requires a greater resolution than a website image.
You do not need design experience to develop packaging that suits your brand. Starting with no more than a logo, our team creates the structure and produces professionally designed, print-ready artwork alongside you, clarifying each technical decision as it arises.
Our online tool lets you to personalise a box and preview its look and feel on screen before it goes to print, while Pantone colour matching ensures each repeat order remains consistent.
If you require packaging printed in both English and Welsh, our team considers this to be a standard artwork requirement and manages it just as we would any other language or colour alteration.
Custom packaging for Abercarn’s businesses
Cuisine and beverages
Welsh Lamb and Welsh Beef have Protected Geographical Indication status, while all food packaging that comes into contact with meat or dairy must satisfy food contact standards, wherever it is manufactured on either side of the border.
We hold BRC Global Packaging certification at High Hygiene level, ensuring our food packaging is made in controlled, traceable conditions reviewed by retailers prior to welcoming products onto their shelves.
Drinks and spirit-making
Over the past two decades, Wales has developed a authentic drinks scene, from distilleries in Brecon Beacons to newer gin and whisky producers farther north.
Bottle presentation boxes must survive transit and appear smart on the shelf as well! Finishes such as foil stamping and embossing create much of the impact for a limited release or seasonal gift set.
Beauty products and personal care of the Abercarn
Cosmetic and skincare brands require cartons that protect delicate glass and compacts whilst looking good on the shelf.
We manufacture cosmetics packaging featuring soft touch lamination, foil and embossing, while rigid boxes complement a premium range that must support a higher price point.
Online commerce and recurring companies
Packaging designed for retail display is important when a product is located in a shop or marketplace fulfilment centre, but subscription brands face an entirely different challenge.
Each month, the same customer revisits an nearly identical box, rendering a reliable finish just as important as the initial design.
High-grade e-commerce packaging, produced precisely to fit your product packaging, holds items safe during transit and lowers damage claims and returns.
A fitted insert or printed tissue holds the product firmly during transit, while the design is immediately visible when the box is opened.
For a subscription-based brand that places repeat orders monthly, keeping consistent box dimensions maintains predictable pallet capacity and warehouse racking, becoming progressively important as volumes surpass several hundred units.
Shipping to Abercarn from our Scottish atelier
All products are manufactured at our Irvine facility, with standard UK delivery to businesses in Abercarn.
The majority of orders reach a Abercarn address within two to three weeks after proof approval, following the same timetable as all our packaging across the UK.
Custom Pack Studio is part of KennedySmith (Press) Ltd, an established packaging manufacturer producing print and packaging since 1997, where an experienced team creates boxes on its own presses.
You receive a proof and, where the format requires it, a physical sample before full production starts. Reorders use the same artwork, so scaling up never requires again.
Using a single box company for packaging throughout your entire product line makes everything straightforward.
You get one invoice and liaise with one contact, steering clear of multiple suppliers quoting different prices for different weeks.
Eco-friendly packaging as routine
Each box we make is 100% recyclable because the board itself is recyclable.
Our board and paper are sourced from FSC and PEFC certified sources, while audits trace every sheet through the supply chain to responsibly managed forests.
We are reducing single use plastic and EPS foam void fill throughout our processes because neither can be readily recycled, and both create difficulties with disposal once a parcel has been opened.
Where the design permits, biodegradable or paper-based protection is employed instead of them.
No minimum order for Abercarn companies
Across much of the industry, custom packaging requires minimum orders of 500 or 1,000 units, requiring you to fund stock and storage before establishing whether a product will sell.
There is no minimum order requirement whatsoever.
Small businesses may order one sample, commission a limited trial run, or proceed with full production after demand is established, with unit pricing scaling at every quantity across this range.
You will consistently receive a written quotation before production begins, while the high quality materials and packaging products provided for a run of fifty are identical to the ones provided for a run of ten thousand.
Prior to placing a bigger order, ask for a printed sample to evaluate the print, colour and how comfortably it fits in your hand.
Steps on how to obtain bespoke parcel materials
Share your brief. Call 01294 314 919 or use the online design tool. Tell us the product, quantity and approximately the way it is sold.
Design and proof. We create packaging suited to your product, prepare the print layout, and provide a proof for you to review.
Ask for a physical sample when the format calls for one. Approve it once you are satisfied with the colour and construction.
Production and delivery. Your order is printed and finished in Irvine, subsequently delivered to your Abercarn address, typically within two to three weeks.
Personalised packaging Abercarn Frequently Asked Questions
Do you deliver custom packaging to Abercarn?
Yes. We make every item in Irvine and offer standard delivery across the UK, serving every part of Abercarn and all of Wales, without adding a separate fee for locations farther from the factory.
What exactly would be the lowest packaging quantity at Abercarn?
No minimum order applies. Whether you need one box or several thousand in any format, you will receive quantity based pricing through a written quotation before production begins.
Which packing elements can I personalise?
Dimensions, structure, board weight, print and finish can all be tailored for every format, ensuring the designed packaging meets your brief exactly. A branded packaging order can also be printed on both the interior and exterior.
Is it possible to we request specimens of your packaging products before ordering?
Yes. You receive a sample printed and finished precisely as it would be in production, allowing you to check that the colours satisfy your brief and the board feels suitable before approving a bulk order.
Could the packaging remain recyclable and can it also be biodegradable?
All boxes are 100% recyclable. We avoid plastic laminates which prevent recycling except when food safety requires them. Biodegradable protective materials are available where the format allows.
Is it possible to one place the same layout order later?
Indeed, repeat orders use the same artwork file, meaning that increasing an order or repeating it for a new season does not require the packaging to be redesigned from the beginning.
Request a free quote from our experts at Custom Pack Studio without delay.
Please call 01294 314 919 or email contact@custompackstudio.co.uk with details of your product, packaging requirements and anticipated quantities.
Order exactly what you need, with no minimum quantity! Every project includes design support, and all custom packaging created here is designed around your product rather than relying on a template.
Send your query and we will provide a written quote.
