Why opt for bespoke packaging?
A conventional box leaves room around the product, making it rattle in transit until foam or paper is added to prevent movement.
Conventional packaging with a label applied to its side may be convenient, but it is intended for no particular audience.
Custom Pack Studio designs customised packaging around your product, making sure the box, print and finish suit your brand rather than overshadowing it.
We produce custom boxes, mailer boxes, gift packaging and printed accessories for businesses throughout Pencoed and the valleys beyond, with orders varying from one sample to a full pallet delivered straight to your warehouse door.
We require no minimum order, so stock and storage costs remain out of the picture until you know whether a product sells.
Share your packaging requirements, and we’ll adapt the recommendation to suit the product itself.
What bespoke packaging entails
Custom packaging shapes the box around your product from the start, with its dimensions and print customised to what you are packing.
You select the dimensions, so that a made-to-measure box holds the product securely rather than letting it rattle within surplus space created by a standard size.
The structure, board weight, print and finish are also custom designed, carefully matched to what is being packed and the way it travels.
Printing a logo onto a stock box creates personalised packaging, requiring less work than a completely customisable design.
Using bespoke packaging, each panel, fold and finish can be customised, even for a single item, enabling you to create packaging that fits exactly without compromise.
Packaging formats we produce for Pencoed companies
We manufacture a wide selection of packaging boxes, each produced to bespoke dimensions and printed in full colour using your artwork.
Selecting the suitable box style and packaging format depends on your products and the way they are handled. Our packaging specialists will guide you through the available options.
Retail cartons and branded packaging
Reverse tuck end cartons are a favourite in retail packaging, well suited for lighter products such as cosmetics and supplements, with flaps that tuck in at both the upper end and lower end.
Crash lock boxes are a type of lock box, offering a stronger cardboard design with a base that snaps flat once opened, stopping heavier products from pushing the bottom out.
Shipping and internet shopping boxes
A custom mailer box protects your product across the courier network while making delivery part of the brand experience and improving visibility, with printing inside and outside instead of only on the outer face.
Gusseted variants of these custom printed boxes provide additional depth, allowing bulkier items space to sit securely without moving.
Present boxes, sturdy boxes and gable-shaped boxes
Rigid boxes, gift boxes with magnetic closures and other branded boxes provide products bought as presents the polished presentation customers anticipate, without customers needing to wrap them.
Gable boxes, featuring a fold up carry handle, are excellent for food presents as well as hampers!
For high-end ranges, we may specify SBS board, that is, solid bleached sulphate, a bright, food safe paperboard, rather than conventional carton stock. Foil and soft touch lamination finishes can enhance further the result.
Develop guidance for your Pencoed brand
Each order includes packaging design assistance, irrespective of how far your artwork has progressed.
If you have a logo and brand guidelines, our design specialists create print ready files and confirm that colours are reproduced accurately on board, because packaging requires higher resolution than a web image.
Previous design experience is not necessary to produce packaging that reflects your brand. We can begin with nothing more than a logo, creating the structure and expertly designed, ready to print artwork with you, while explaining each technical decision clearly as it arises.
Our online tool allows you to customise a box and check its appearance on screen prior to printing, while Pantone colour matching ensures that repeat orders remain consistent.
When your packaging needs English and Welsh text, our staff manages this as a routine artwork request, just as we would handle any other language or colour amendment.
Custom packaging for the Pencoed’s businesses
Food and beverages
Welsh Lamb and Welsh Beef have Protected Geographical Indication status, whereas all food packaging that is in contact with meat or dairy must satisfy food contact standards, wherever 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 manufactured in controlled and traceable conditions that retailers verify before listing products.
Beverages and liquor producers
During the last two decades, Wales has built a real drinks scene, encompassing Brecon Beacons distilleries and more recent gin and whisky producers across the north.
Bottle presentation boxes have to withstand transit and appear smart on the shelf too! Finishes including foil stamping and embossing deliver much of the impact for a limited release or seasonal gift set.
Beauty products and personal care products for Pencoed
Cosmetic and skincare brands need cartons that safeguard delicate glass and compacts while standing out on the shelf.
We manufacture cosmetics packaging with soft touch lamination, foil and embossing, while rigid boxes pair with premium ranges intended to support a higher price point.
Online shopping and subscription labels
Retail ready and display packaging plays its part when products are placed on shop shelves or marketplace fulfilment centres, but subscription brands face an wholly different challenge.
As the same customer unpacks an almost identical box every month, preserving a consistent finish is as important as the initial design.
Accurately sized e commerce packaging keeps products safely in transit, helping to prevent damage, reduce claims and limit returns.
A fitted insert or printed tissue holds the product securely in transit, while the design is straight away visible once the box is opened.
For a subscription brand that places monthly reorders, using consistent box dimensions keeps pallet space and warehouse racking predictable, an ever more valuable benefit once volumes exceed a few hundred units.
Sending to Pencoed from our Scottish facility
Everything is made at our Irvine facility, with standard UK delivery to businesses in Pencoed.
Most orders reach a Pencoed address within two to three weeks after proof approval, following the same schedule as our packaging throughout the UK.
Custom Pack Studio is owned by KennedySmith (Press) Ltd, a packaging manufacturer producing print and packaging since 1997, which means an established team produces the boxes with its own presses.
You sign off on a proof and, where required by the format, a physical sample before full production starts, while reorders keep the original artwork, meaning larger quantities require no fresh preparation.
Working with a single box company for packaging throughout your whole product line makes everything uncomplicated.
You receive one invoice and operate through a single point of contact, rather than pursuing multiple suppliers, each quoting different prices for individual weeks.
Green packaging as usual practice
Each box we produce is 100% recyclable as the board itself is recyclable.
Our board and paper are sourced from FSC and PEFC certified sources, whilst an audited supply chain traces every sheet back to responsibly managed forests.
We are cutting down on single use plastic and EPS foam void fill across our processes because neither can be readily recycled, and both cause disposal difficulties after a parcel has been opened.
Where the design allows, biodegradable or paper-based protective materials are used in their place.
No minimum purchase for Pencoed organisations.
Throughout much of the industry, custom packaging demands minimum orders of 500 or 1,000 units, leaving you to finance stock and storage before determining whether the product will sell.
There is no minimum order requirement of any kind!
Small businesses may order a single sample, limited runs for testing, or a full production run once demand has been established, with the unit price varying according to the quantity ordered.
You are sent a written quote before production begins, while the high-quality materials and packaging products supplied for a run of fifty are identical to those provided for a run of ten thousand.
Before ordering in bulk, request a printed sample and examine its print, colour and how it sits in your hand.
Methods to order bespoke packaging
Provide your brief by calling 01294 314 919 or using the online design tool, then let us know the product, quantity, and approximately how it is sold.
Design and proof. We develop packaging suited to your product, produce the print layout, and provide a proof for you to review.
Ask for a physical sample if the format calls for one, then sign off once you are satisfied with the colour and construction.
Production and delivery. Your order is printed and finished in Irvine before being delivered to your Pencoed address, typically within two to three weeks.
Bespoke packaging Pencoed Common Questions
Does your company offer personalised packaging distribution to Pencoed?
Yes. We make all items in Irvine and offer standard delivery across the UK, serving every part of Pencoed and the whole of Wales, without adding a separate fee for locations more distant from the factory.
Which represents the smallest packaging amount at Pencoed?
No minimum order. We can manufacture one box or thousands in whatever format, with quantity-based pricing confirmed in a written quotation before manufacture starts.
Which sections of the packaging can be customised?
Each aspect of the format, including size, structure, board weight, print and finish, can be adjusted, so that the packaging matches exactly your brief. Branded packaging may also be printed internally and externally.
Can you kindly send samples of your packaging products before I choose to place an order?
Yes. The sample is printed and finished to precisely the same standard as a production run, allowing you to verify that the colours meet your brief and that the board has the correct feel before authorising a bulk order.
Can the packaging be recyclable as well as will it decompose?
Every box is 100% recyclable. We do not use plastic laminates that prevent recycling except when food safety requires them. Biodegradable protective materials are available where the format allows.
Is it possible to someone place another order for the same design in the future?
Yes, repeat orders continue using the same artwork file, meaning you can raise quantities or get packaging ready for a new season without redesigning everything from scratch.
Ask for a complimentary quotation from our Custom Pack Studio experts immediately
Please telephone 01294 314 919 or email contact@custompackstudio.co.uk, providing your product details, packaging requirements and anticipated quantities.
Order exactly what you need, with no minimum quantity! Every project includes design support, and all custom packaging made here is designed around your product rather than relying on a template.
Submit your enquiry and we will provide a written quote.
