Reasons choose personalised packaging
A regular box leaves empty space around the product, allowing it to rattle during transport until somebody fills the gap with foam or paper to prevent it from moving.
Conventional packaging with a label affixed to its side might be convenient, but it is designed for no specific audience.
Custom Pack Studio creates bespoke packaging for your product, making sure that the box, print and finish complement your brand rather than overshadowing it.
We create custom boxes, mailer boxes, gift packaging and printed accessories for companies throughout Llanwern and the valleys beyond. Orders can be as small as one sample or as large as a pallet delivered straight to your warehouse door!
We require no minimum order for any item we produce, enabling you to avoid stock and storage costs until a product’s sales potential is determined.
Share your packaging requirements, and we’ll tailor the recommendation to suit the product itself.
What custom packaging entails
Custom packaging shapes the box around your product from the start, with its dimensions and print tailored to what you are packing.
You choose the dimensions, allowing a custom-sized box to keep the product securely without movement resulting from excess space in a standard size.
Each aspect, including the construction, board weight, printing and finish, is adapted to the contents and the way they are transported.
Printing your logo on a stock box results in personalised packaging, involving less work than a completely customisable design.
With customised packaging, each panel, fold and finish can be customised, even for a single item, enabling you to create packaging that fits exactly and with no compromise.
Packing solutions we produce for Llanwern businesses
We produce a full range of packaging boxes, tailored to bespoke sizes and printed in full colour using your artwork.
Selecting the correct box style and packaging type depends on your product and the way it is handled. Our packaging specialists will take you through the options available.
Store cartons and labelled packaging
Reverse tuck end cartons are a conventional retail packaging type for lighter products, such as cosmetics and supplements, with flaps that tuck into place at both the top and bottom.
Crash lock boxes are more robust cardboard lock boxes with a base that snaps flat upon opening, preventing heavier items from forcing the bottom out.
Postal and ecommerce boxes
A custom mailer box safeguards your product across the courier network, while turning delivery into part of the brand experience and boosting visibility through printing on both its interior and exterior, not just its outer face.
Gusseted versions of these custom printed boxes provide additional depth, allowing bulkier items to sit securely without shifting.
Gift packages, solid boxes and gable packages
Rigid boxes, magnetic closure gift boxes along with additional branded boxes give purchases made as gifts with the presentation customers expect, without them needing to wrap anything themselves.
Gable boxes, supplied with a handle that folds up, are an excellent choice for food gifts and hampers.
For premium ranges, we sometimes specify SBS board, or solid bleached sulphate, a bright, food-safe paperboard, rather than standard carton stock, while finishes such as foil and soft touch lamination enhance the overall effect.
Design guidance for your Llanwern business
Every order provides packaging design support, regardless of how far your artwork has progressed.
If you’ve got a logo and brand guidelines, our design specialists prepare print-ready files and check that the colours stay accurate on board, because packaging needs a greater resolution than a website image.
You do not need design experience to create packaging that fits your brand. Our team can begin with only a logo. Working together, they determine the structure and create expertly designed, print ready artwork, detailing each technical decision as the project progresses.
Our online tool allows you to customise a box and preview its look on screen before printing, while Pantone colour matching maintains consistency whenever you make a repeat order.
If packaging is required in both English and Welsh, our team regards this as a standard artwork requirement, managing it exactly as it would any other language or colour change.
Tailored packaging for Llanwern’s unique industries
Food and refreshments
Welsh Lamb and Welsh Beef both hold Protected Geographical Indication status, while all food packaging that contacts meat or dairy must meet food contact standards, regardless of where it is manufactured.
We have BRC Global Packaging certification at High Hygiene level, which means our food packaging is made in controlled and traceable conditions that retailers verify prior to listing products.
Drinks and spirit-making locations
Across Wales, a thriving drinks culture has developed during the past twenty years, stretching from Brecon Beacons distilleries to more recent gin and whisky makers in the north.
Presentation boxes for bottles need to endure transit while remaining striking on the shelf, with finishes such as foil stamping and embossing bringing much of the impact to a limited release or seasonal gift set.
Skincare and beauty products
Cosmetic and skincare brands need cartons that safeguard delicate glass and compacts whilst presenting well on the shelf.
We produce cosmetics packaging with soft touch lamination, foil and embossing, whereas rigid boxes suit premium ranges that need to support a higher price point.
Online shopping and subscription labels
Packaging designed for retail shelves or marketplace fulfilment centres is important, yet, subscription brands encounter a distinct challenge.
Every month, the same customer returns to an nearly identical box, making a dependable finish just as important as the initial design.
Accurately sized e commerce packaging holds products safely in transit, helping prevent damage, reduce claims and limit returns.
A fitted insert or printed tissue keeps the product secure in transit, while the print stays visible as soon as the box is opened.
Subscription brands that reorder monthly can maintain pallet space and warehouse racking consistent by retaining one box size. This becomes increasingly important when order volumes exceed several hundred units.
Transporting to Llanwern from our Scotland studio
All items is made at our Irvine facility, with UK delivery to companies in Llanwern provided as standard.
Once your proof is approved, most orders are delivered to a Llanwern address within two to three weeks, matching the delivery timescale for our packaging across the UK.
Custom Pack Studio is part of KennedySmith (Press) Ltd, a packaging manufacturer producing print and packaging since 1997. Its long-standing team produces the boxes using its own presses.
You receive a proof and, where required by the format, a physical sample before full production starts. Reorders use the same artwork, making it possible to scale up without restarting the process again.
Employing a sole box company for packaging across your entire product range makes the process straightforward.
It all flows through a single invoice and a single point of contact, sparing you the frustration of chasing multiple suppliers quoting different prices for separate weeks.
Earth-friendly packaging as commonplace
Every box we produce is 100% recyclable as the board itself makes possible that recyclability.
Our board and paper are sourced from FSC and PEFC certified suppliers, with each sheet tracked through an audited supply chain to responsibly managed forests.
We are reducing single use plastic and EPS foam void fill throughout our processes, as neither material is easy to recycle and both cause disposal difficulties after a parcel has been opened.
Where the design allows, biodegradable or paper-based protective materials are employed in their place.
There is no minimum purchase for Llanwern enterprises.
Throughout much of the industry, custom packaging requires minimum orders of 500 or 1,000 units, requiring you to finance stock and storage prior to establishing whether a product will sell.
There is no minimum order requirement at all.
Smaller businesses may place an order for a single sample, a limited run for testing, or a full production run once demand has been established, with the price per unit varying at each quantity across this range.
Prior to production begins, you will always receive a written quotation, while the high-quality materials and packaging products supplied for a run of fifty remain identical to those provided for a run of ten thousand.
Before placing a bigger order, ask for a printed sample to evaluate the print, colour and how comfortably it sits in your hand.
How to place a custom packing order
Provide your brief by telephoning 01294 314 919 or accessing the online design tool. Tell us the product, quantity needed, and roughly how it is sold.
Design and proof. We develop packaging design suited to your product, arrange the print layout, and provide a proof for you to check.
Ask for and approve a sample. If the format calls for one, order a physical sample, then sign off when you are happy with the colour and construction.
Production and delivery. Your order is printed and completed in Irvine prior to being delivered to your Llanwern address, generally within two to three weeks.
Tailored packaging Llanwern Frequently Asked Questions
Will you provide tailored packaging to Llanwern?
Yes! We manufacture everything in Irvine and deliver across the UK as standard, including every part of Llanwern and across Wales, with no additional charge solely because you are farther from the factory.
What’s is the minimum packaging order in Llanwern?
There is no minimum order requirement. You can order a single box or several thousand in whatever format, with pricing based on quantity and confirmed in writing before production begins.
Which packing elements can I personalise?
Size, structure, board weight, print and finish can all be altered for every format, making sure the packaging meets your brief exactly. Branded packaging can additionally feature printing on both the inside and exterior.
May one request examples of your parcel products before ordering?
Yes. The sample is printed and finished to precisely reproduce a production run, enabling you to verify that its colours meet your brief and that the board feels suitable before approving a bulk order.
Could the packaging recyclable and can it be compostable?
Every packaging box is fully recyclable. We omit plastic laminates that prevent recycling, except where food safety requires them, while biodegradable protective materials are made available when the format permits.
May I order again the same layout later?
Certainly, reorders rely on the original artwork file, allowing you to increase an order or prepare for another season without having to redesign the packaging.
Obtain a cost-free quotation from Custom Pack Studio straight away.
Please call 01294 314 919 or email contact@custompackstudio.co.uk with details of your product, packaging requirements and anticipated quantities.
We set no minimum order. Each project includes design support, and every item of custom packaging we produce here is developed around your product, not a template.
Begin your enquiry, and we will reply with a written quotation.
