Motives choose bespoke packaging
A standard box provides room around the product, allowing it to rattle during transit until foam or paper is introduced to prevent movement.
Conventional packaging with a side sticker is the simplest approach, but it serves no particular customer.
Custom Pack Studio creates bespoke packaging tailored to your product, making sure the box, print and finish support your brand rather than overshadowing it.
We produce custom boxes, mailer boxes, gift packaging and printed accessories for businesses across Old St Mellons and the valleys beyond. Orders can be as small as one sample or as large as a pallet delivered directly to your warehouse door!
We do not require a minimum order for any item we make, enabling you to avoid stock and storage costs until a product’s sales potential is determined.
Tell us about your packaging needs, and we will customise the recommendation to suit the product itself.
What bespoke packaging implies
With custom packaging, your box is created around the product from day one, so its dimensions and print fit precisely what you are packing.
Select the measurements, allowing a custom-sized box to hold the product firmly without avoidable 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 a logo on a stock box amounts to personalised packaging, a more limited undertaking than entirely customisable design.
Using customised packaging, you can modify each panel, fold and finish, even with a single run, producing packaging that fits without compromise.
Packaging types we provide for Old St Mellons firms
We create a full range of packaging boxes, made to custom sizes and printed in full colour using your artwork!
The ideal box design and packaging type depend on what you sell and the way it is handled, while our packaging experts will talk you through the choices!
Retail cartons and bespoke branded packaging
Reverse tuck end cartons are a popular choice for retail packaging, well suited for low-weight products like cosmetics and supplements, featuring flaps that tuck in at both the top and bottom.
Crash lock boxes are a sturdier type of lock box, formed from cardboard and having a base that snaps flat when opened, preventing heavier products from forcing the bottom out.
Mailer and ecommerce boxes
A bespoke mailer box safeguards your product across the courier network, turning delivery into an exciting part of the brand experience while increasing visibility by printing on both the inside and outside, not merely the outer face.
Gusseted versions of these custom printed boxes provide additional depth, allowing bulkier items room to rest securely without shifting.
Present boxes, rigid boxes and gable boxes
Rigid boxes, gift boxes with magnetic closures and other branded boxes give products bought as gifts the polished presentation customers expect, without customers needing to wrap them.
Gable boxes, with a fold up carry handle, are great for food presents as well as hampers!
For premium ranges, we occasionally specify SBS board, or solid bleached sulphate, a bright, food-safe paperboard, instead of standard carton stock, while finishes such as foil and soft touch lamination enhance the overall effect.
Build aid for your Old St Mellons business
Every order includes packaging design assistance, irrespective of how far your artwork has progressed.
If you have a logo and branding guidelines, our design experts prepare print-ready files and verify that colours are reproduced accurately on board, as packaging needs higher resolution than website imagery.
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 professionally designed artwork prepared for print working with you, explaining each technical decision when it arises.
Our online tool enables you to personalise a box and preview its look on screen before printing, while Pantone colour matching maintains consistency each time you place a repeat order.
When your packaging requires English and Welsh text, our staff manages this as a routine artwork request, just as we would manage any other language or colour amendment.
Specialised packaging for Old St Mellons’s sectors
Food and drink
Welsh Lamb and Welsh Beef hold Protected Geographical Indication status, while all food packaging that comes into contact with meat or dairy must satisfy food contact standards, regardless of where it is manufactured on either side of the border.
We have BRC Global Packaging certification at High Hygiene level, which means our food packaging is made in controlled, traceable conditions that retailers verify before listing products.
Drinks and distillation
During the past two decades, Wales has developed a real drinks scene, spanning Brecon Beacons distilleries and newer gin and whisky producers across the north.
Bottle presentation boxes need to withstand transit while retaining shelf appeal, with finishes including foil stamping and embossing delivering much of the impact for a limited release or seasonal gift set.
Beauty products and grooming products for Old St Mellons
Cosmetic and skincare brands need cartons that shield delicate glass containers and compacts, while creating an appealing presentation on retail shelves.
We produce cosmetics packaging with soft touch lamination, foil and embossing, while rigid boxes are suited to premium ranges requiring a higher price point to be justified.
Online shopping and membership brands
Retail ready and display packaging are important when products occupy shops or marketplace fulfilment centres, but subscription brands encounter a distinct challenge.
Because the same customer opens an nearly identical box every month, keeping a consistent finish is as important as the original design.
Effective online retail packaging, made to match your product packaging exactly, keeps goods secure during transit and reduces damage claims and returns.
Inside, a fitted insert or printed tissue keeps the product securely during transit, as the print greets the eye the moment the box opens.
Subscription brands that reorder each month can keep pallet space and warehouse racking uniform by retaining one box size. This becomes more important over time when order volumes exceed several hundred units.
Transporting to Old St Mellons from our Scottish atelier
Everything is manufactured at our Irvine facility, with UK delivery to businesses in Old St Mellons provided as standard.
The majority of orders arrive at a Old St Mellons address within two to three weeks following proof approval, following the same timetable as all our packaging throughout the UK.
Custom Pack Studio is part of KennedySmith (Press) Ltd, an established packaging manufacturer producing print and packaging since 1997, where a seasoned team creates boxes using its own presses.
Prior to the start of full production, you get a proof and, when the format requires it, a physical sample, as reorders keep the same artwork, rendering expansion remarkably simple.
Employing one box company for packaging throughout your whole range of products makes everything simple.
You have one invoice and one contact, avoiding the need to chase multiple suppliers quoting different prices for different weeks.
Renewable packaging as the norm
Every box we make is 100% recyclable as the board itself is recyclable.
Our board and paper are procured from FSC and PEFC certified suppliers, with every sheet traceable via an audited chain to responsibly managed forests.
We are reducing single use plastic and EPS foam void fill across our processes because neither is readily recyclable, creating disposal difficulties after a parcel is opened.
Where the design permits, biodegradable or paper-based protection is employed instead of them.
No minimum purchase for Old St Mellons businesses
Across much of the industry, custom packaging requires minimum orders of 500 or 1,000 units, requiring you to finance stock and storage before determining whether a product will sell.
We do not have a minimum order requirement.
Smaller businesses can begin with a single sample, place a limited trial run, or proceed with full production once demand is established, while unit pricing scales across every quantity in between.
Prior to production starts, you will always receive a written quotation. The high quality materials and packaging products provided for a run of fifty are exactly the same as those provided for a run of ten thousand.
Before ordering in volume, ask for a printed sample to inspect the print, colour and fit in your hand.
How to obtain bespoke packs
Share your brief. Call 01294 314 919 or use the online design tool, then tell us the product, quantity and the way it is sold.
Design and proof. We develop packaging that suits your product, prepare the print layout, then provide you with a proof to check.
Request a physical sample where the format calls for one, then provide approval once you are happy with its colour and construction.
Production and delivery: Your order is printed and completed in Irvine, and then delivered to your Old St Mellons address, usually within two to three weeks.
Personalised packaging Old St Mellons Frequently Asked Questions
Do you all offer tailored packaging despatch to Old St Mellons?
Yes. We manufacture all items in Irvine and provide standard delivery throughout the UK, including every part of Old St Mellons and Wales, without an extra charge simply because of the distance from our factory.
What is the minimum packaging quantity at Old St Mellons?
No minimum order is required. You can request one box or several thousand in any format, with pricing adjusted according to quantity in a written quote issued before production begins.
Which packing elements can I customise?
Dimensions, structure, board weight, print and finish can all be tailored for every format, making sure the designed packaging meets your brief exactly. A branded packaging order can also be printed on both the inside and exterior.
Is it possible that I receive examples of your packaging materials before making an order?
Yes. You get a sample printed and finished exactly as it would be in production, enabling you to check that the colours satisfy your brief and the board feels suitable before authorising a bulk order.
Will the packaging turn out to be recyclable plus can it prove 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 allows.
May someone reorder the same design at a later date?
Yes, reorders are made from the same artwork file, so expanding an order or repeating it for a new season never requires the packaging to be redesigned from the beginning.
Get a free pricing from the Custom Pack Studio team now
Contact us on 01294 314 919 or at contact@custompackstudio.co.uk, providing your product, packaging requirements and intended quantities.
There is no minimum order requirement, design support is included in each project, and every item of custom packaging produced here is developed around your product rather than a conventional template.
Send your query and we will provide a written quotation.
