Why select made-to-measure packaging
A conventional box provides space around the product, allowing it to rattle in transit until foam or paper is added to prevent movement.
Conventional packaging with a sticker is simple, but it is designed for no one in particular.
Custom Pack Studio creates bespoke packaging particularly for your product, ensuring the box, print and finish uphold your brand rather than overshadowing it.
We make bespoke boxes, mailer boxes, gift packaging and printed accessories for companies across Merthyr Tydfil and the nearby valleys, with order quantities spanning one sample to a pallet load delivered straight to a warehouse door.
We have no minimum order, so stock and storage costs remain out of the equation until you know whether a product sells.
Tell us your packaging requirements, and we will customise the recommendation to fit the product perfectly.
What bespoke packaging entails
With custom packaging, your box is created around the product from the outset, so its dimensions and print suit exactly what you are packing.
You select the dimensions, allowing a made-to-measure box to hold the product firmly without movement caused by excess space in a standard size.
The structure, board weight, print and finish are custom designed to suit what is packed and how it travels.
Printing a logo on a stock box creates personalised packaging, offering a more modest project than fully customisable design.
With tailored packaging, each panel, fold and finish can be adjusted, even for just one unit, allowing you to create custom packaging that fits exactly.
Wrapping solutions we offer for Merthyr Tydfil businesses
We manufacture a full range of packaging boxes, made to bespoke sizes and printed in full colour with your artwork.
Selecting the appropriate box style and packaging is based on what you sell and how it is handled, while our packaging specialists will take you through the available options.
Shop cartons and personalised branded packaging
Reverse tuck end cartons remain a well-known retail packaging choice for lightweight products, such as cosmetics and supplements, featuring flaps that fold tidily into both the top and bottom.
Crash lock boxes are a sturdier type of lock box, made from cardboard and featuring a base that snaps flat when opened, preventing heavier products from pushing the bottom out.
Shipping and ecommerce boxes
A custom mailer box safeguards your product across the courier network while making delivery part of the brand experience and enhancing visibility, with printing inside and outside rather than only on the outer face.
Gusseted versions of these custom printed boxes offer extra depth, allowing bulkier items space to sit securely without shifting.
Gift boxes, sturdy boxes and carton boxes
Rigid boxes, gift boxes with magnetic closures and additional branded boxes give presents a refined presentation customers expect, without them needing to wrap anything themselves.
Gable boxes featuring folding carry handles are suitable for food gifts and hampers.
For premium ranges, we may specify SBS board, that is, solid bleached sulphate, a light-coloured, safe for food contact paperboard, instead of standard carton stock. Foil and soft touch lamination can further enhance the finish.
Build help for your Merthyr Tydfil enterprise
Each order includes packaging design support, irrespective of how far your artwork has developed.
If you have a logo and brand guidelines, our design experts prepare print-ready files and verify that the colours remain accurate on board, because packaging requires a higher resolution than a website image.
You do not need previous design experience to create packaging that reflects your brand. Our team can begin with just a logo, establish the structure and produce expertly designed artwork ready for print in collaboration with you, clarifying each technical decision as it arises.
Our web-based tool lets you to personalise a box and preview its look and feel on screen before it reaches print, while Pantone colour matching ensures every repeat order remains consistent.
When your packaging requires English and Welsh text, our team manages this as a standard artwork request, just as we would manage any other language or colour amendment.
Tailored packaging for Merthyr Tydfil’s specialised industries
Cuisine and refreshments
Welsh Lamb and Welsh Beef both have 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 hold BRC Global Packaging certification at High Hygiene level, meaning our food packaging is manufactured in controlled, traceable conditions that retailers review before listing products.
Tipples and distilleries
Over the past twenty years, Wales has established a distinctive drinks industry, spanning distilleries in the Brecon Beacons and newer gin and whisky producers across the north.
Bottle presentation boxes must withstand transit while retaining shelf appeal, with finishes including foil stamping and embossing providing much of the impact for a limited release or seasonal gift set.
Beauty products and skincare essentials
Cosmetic and skincare brands require cartons that protect delicate glass containers and compacts, whilst creating an attractive display on retail shelves.
We manufacture cosmetics packaging with soft touch lamination, foil and embossing, whereas rigid boxes give premium ranges the presence to support a higher price point.
E-commerce and recurring businesses
Retail ready and display packaging are important when products occupy shops or marketplace fulfilment centres, but subscription brands encounter a distinct challenge.
As the same customer opens up an almost identical box each month, maintaining a consistent finish is as important as the original design.
Effective ecommerce packaging, precisely tailored to your product packaging, keeps items secure in transit while reducing damage claims and returns.
A fitted insert or printed tissue keeps the product securely in transit, while the design is straight away visible when the box opens.
When a subscription brand places repeat orders each month, maintaining uniform box dimensions makes pallet capacity and warehouse racking predictable, an increasingly important consideration once volumes exceed several hundred units.
Delivering to Merthyr Tydfil from our Scotland workshop
Everything is made at our Irvine facility, with delivery throughout the UK to businesses in Merthyr Tydfil included as standard.
The majority of orders reach a Merthyr Tydfil address within two to three weeks after proof approval, using the same timetable as all our packaging across the UK.
Custom Pack Studio belongs to KennedySmith (Press) Ltd, a packaging manufacturer producing print and packaging since 1997, meaning an long-standing team makes the boxes with its own presses.
You will review a proof and, when required by the format, a physical sample before full production starts. Reorders use the same artwork, so scaling up never means beginning from scratch!
Using a single box company for your entire product range makes packaging.
Everything passes through a single invoice and one point of contact, saving you from the frustration of pursuing several suppliers quoting different prices for separate weeks.
Eco-friendly packaging as the norm
Each box we produce is 100% recyclable since the board itself is recyclable.
Our board and paper are sourced from FSC and PEFC certified sources, while audits track each sheet through the supply chain to responsibly managed forests.
We are reducing single use plastic and EPS foam void fill throughout our processes as neither is readily recyclable, creating disposal difficulties after a parcel is opened.
Where the design allows, biodegradable or paper-based protection is used in place of them.
No minimum purchase for Merthyr Tydfil companies
Throughout the wider industry, custom packaging frequently requires minimum orders of 500 or 1,000 units, requiring you to finance stock and storage before knowing whether a product will sell.
We have no minimum order requirement.
Smaller businesses can choose a one sample, a short trial run, or a full production run after demand is proven, with per-unit pricing scaling across every quantity in between.
Prior to production starts, you will always receive a written quotation, while the high-quality materials and packaging products provided for a run of fifty remain identical to those supplied for a run of ten thousand.
Prior to placing a bigger order, ask for a printed sample to assess the print, colour and how comfortably it fits into your hand.
Methods to place a personalised packaging order
Provide your brief by telephoning 01294 314 919 or using the online design tool. Tell us the product, quantity required, and approximately how it is sold.
Design and print proofing. We design packaging that fits your product, produce the print layout, and supply a proof for your approval.
Ask for a physical sample if 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 Merthyr Tydfil address, usually within two to three weeks.
Custom packaging Merthyr Tydfil FAQ
Will you send bespoke packaging to Merthyr Tydfil?
Yes. We manufacture every item in Irvine and offer standard delivery throughout the UK, serving every part of Merthyr Tydfil and the whole of Wales, without adding a separate fee for locations farther from the factory.
How many might be the least parcel quantity for Merthyr Tydfil?
No minimum order. We can manufacture a single box or thousands in any format, with quantity-based pricing confirmed in a written quotation before manufacture begins.
Which parts of the packaging can be personalised?
Size, structure, board weight, print and finish can all be altered for each format, ensuring the packaging meets your brief precisely. Branded packaging can additionally feature printing on both the interior and exterior.
Might I receive samples of your packaging products before confirming an order?
Yes. The sample is printed and finished to precisely replicate a production run, allowing you to confirm that its colours meet your brief and that the board feels suitable prior to approving a bulk order.
Is the packaging suitable for recycling and biodegradable?
Every box is completely recyclable. We steer clear of plastic laminates that prevent recycling, unless food safety makes them necessary, while biodegradable protective materials are provided wherever the format permits.
Is it possible to one submit the same design at a later time?
Yes, repeat orders continue using the same artwork file, meaning you can increase quantities or get packaging ready for a new season without redesigning everything from the beginning.
Request a without charge quotation from Custom Pack Studio right away
Please telephone 01294 314 919 or email contact@custompackstudio.co.uk, providing your product details, packaging requirements and anticipated quantities.
There is no minimum order, design guidance is provided with every project, and each item of custom packaging produced here is developed around your product instead of a standard template.
Submit your query and we will provide a written quote.
