Why go with personalised packaging
A conventional box leaves room around the product, making it rattle in transit until foam or paper is packed in to prevent movement.
Standard packaging with a label applied to its side may be convenient, but it is designed for no particular audience.
Custom Pack Studio creates bespoke packaging around your product, ensuring the box, print and finish support your brand rather than covering it.
We make custom-made boxes, mailer boxes, gift packaging and printed accessories for companies throughout Rogerstone and the nearby valleys, with order quantities ranging from one sample to a pallet load delivered directly to a warehouse door.
We have no minimum order for anything we make, meaning you avoid stock and storage costs until a product proves it sells.
Tell us about your packaging requirements, and we will customise the recommendation to fit the product itself.
What personalised packaging consists of
Custom packaging designs the box around your product from the outset, so its size and printing correspond exactly to what you are packing.
You choose the dimensions, allowing a made-to-measure box to keep the product securely without movement caused by surplus space in a standard size.
Every aspect, including the construction, board weight, printing and finish, is adapted to the contents and the way they are transported.
Printing a logo onto a stock box produces personalised packaging, needing less work than a completely customisable design.
Using bespoke packaging, every panel, fold and finish can be tailored, even for a single item, enabling you to create packaging that fits perfectly without compromise.
Packing styles we create for Rogerstone businesses
We make a full range of packaging boxes in bespoke sizes, printed in full colour using your artwork.
Choosing the right box style and packaging is based on what you sell and how it is handled, while our packaging experts will guide you through the options available.
Retail boxes and logo packaging
Reverse tuck end cartons are a widely used retail packaging option, suited to lightweight products such as cosmetics and supplements, with closure flaps folding into both the top and bottom.
Crash lock boxes are a more robust type of lock box, made from cardboard with a base that snaps flat upon opening, meaning that heavier products cannot force the bottom out.
Postal and ecommerce boxes
A custom 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 only on the outer face.
Gusseted versions of these custom printed boxes provide additional depth, allowing bulkier items space to sit securely without moving.
Keepsake boxes, hard boxes and pitched-top boxes
Rigid boxes, gift boxes with magnetic closures and other branded boxes give products bought as gifts the polished presentation customers anticipate, without customers needing to wrap them.
Gable boxes, including a fold up carry handle, are suitable for food presents and hampers.
For premium 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.
Build support for your Rogerstone identity
We provide packaging design support with each order, regardless of your artwork’s current stage.
If you have a logo and brand guidelines, our design experts prepare print-ready files and check that colours are reproduced accurately on board, as packaging needs greater resolution than website imagery.
You need not have any prior design experience to develop packaging that represents your brand. We can start with only a logo. Together, you will determine the structure and produce professionally designed, print ready artwork, while we explain every technical decision as it arises.
Our web-based tool allows you to personalise a box and preview its look and feel on screen before it is printed, while Pantone colour matching ensures each repeat order remains consistent.
When you require packaging printed bilingually in English and Welsh, our team considers this as a standard artwork requirement, handled in precisely the same way as any other language or colour change.
Tailored packaging for Rogerstone’s sectors
Meals and refreshments
Welsh Lamb and Welsh Beef both hold Protected Geographical Indication status, while all packaging that is in contact with meat or dairy must meet food contact requirements, irrespective of which side of the border it is manufactured.
Our BRC Global Packaging certification at High Hygiene level verifies that food packaging is produced within controlled and traceable processes, satisfying the checks retailers undertake before approving products for listing.
Beverages and liquor makers
Over the past two decades, Wales has established a flourishing drinks scene, spanning Brecon Beacons distilleries and newer gin and whisky producers in the north.
Bottle presentation boxes need to withstand transit while retaining shelf appeal, with finishes such as foil stamping and embossing providing much of the impact for a limited release or seasonal gift set.
Cosmetics and cosmetic items
Cosmetic and skincare brands need cartons that safeguard delicate glass and compacts while standing out on the shelf.
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.
Electronic commerce and recurring payment brands
Packaging created for retail shelves or marketplace fulfilment centres is important, however, subscription brands experience a specific challenge.
Every month, the same customer opens an almost identical box, rendering a consistent finish every bit as important as the original design.
Efficient online retail packaging, produced to match your product packaging exactly, keeps goods protected during transit and reduces damage claims and returns.
A bespoke insert or printed tissue secures the product during transit, whilst ensuring the print stays immediately visible as the box opens.
For a subscription-based brand that reorders monthly, keeping uniform box dimensions preserves predictable pallet capacity and warehouse racking, becoming increasingly important as volumes exceed several hundred units.
Delivering to Rogerstone from our Scotland workshop
All items is produced at our Irvine facility, with UK delivery to businesses in Rogerstone provided by default.
After proof approval is confirmed, most orders reach at a Rogerstone address in two to three weeks, on the same timetable as the rest of our packaging throughout the UK.
Custom Pack Studio forms part of KennedySmith (Press) Ltd, a packaging manufacturer producing print and packaging since 1997. Its long-standing team makes the boxes using its own presses.
You examine a proof and, when required by the format, a physical sample before full production begins, while reorders use the same artwork, ensuring that scaling up never requires the process to begin again.
Using a sole box company for your full product range makes packaging.
You get one invoice and liaise with one contact, avoiding multiple suppliers quoting different prices for different weeks.
Ethical packaging as routine
Each box we make is entirely recyclable, because of the board it is made from.
Our board and paper are obtained from FSC and PEFC certified suppliers, with every sheet tracked via an audited supply chain to responsibly managed forests.
We are cutting back on single use plastic and EPS foam void fill across our processes, as neither material is readily recyclable and both create disposal difficulties after a parcel has been opened.
When the design permits, biodegradable or paper-based protective materials are employed in their place.
Zero minimum order size for Rogerstone firms
Throughout the industry, custom packaging often demands minimum orders of 500 or 1,000 units, meaning you must fund stock and storage before discovering whether your product will sell.
There is no minimum order requirement .
Smaller businesses can opt for a one sample, a short trial run, or a complete production run after demand is demonstrated, with per-unit pricing scaling across every quantity in between.
You will always receive a written quotation prior to production commencing, while the high quality materials and packaging products supplied for a run of fifty are identical to the ones supplied for a run of ten thousand.
Prior to making a bigger order, ask for a printed sample to evaluate the print, colour and how comfortably it fits in your hand.
Methods to order tailor-made packaging
Provide your brief. Call 01294 314 919 or use the online design tool. Tell us the product, quantity and roughly how it is sold.
Packaging design and proofing. We create the packaging design suited to your product, prepare the print layout, and provide a proof for your approval.
Request a physical sample if the format requires one. Approve it once you are satisfied with the colour and construction.
Production and delivery. Your order is printed and finished in Irvine before making its way to your Rogerstone address, usually within two to three weeks.
Bespoke packaging Rogerstone FAQs
Do you produce made-to-order packaging to Rogerstone?
Certainly. We manufacture each item in Irvine, with standard delivery offered across the UK, including every part of Rogerstone and Wales, with no an extra charge for greater distance from the factory.
What the smallest order for packaging with Rogerstone?
There is no minimum order requirement. You can order one box or several thousand in whatever format, with pricing based on quantity and confirmed in writing before production starts.
Which packing parts can I personalise?
Each format gives you complete freedom to alter the size, structure, board weight, print and finish, making sure the resulting packaging meets your brief precisely. Your branded packaging order can also be printed on the inside as well as the exterior.
May I request examples of your packaging items before submitting an order?
Certainly! Your sample arrives printed and finished precisely as it would be in production, enabling you to check the colours meet your brief and make sure the board feels right before authorising a bulk order.
Is the container able to be recycled and environmentally friendly?
All packaging boxes are fully recyclable. We omit plastic laminates that prevent recycling, except where food safety makes them necessary, while biodegradable protective materials are made available when the format permits.
Is it possible to someone place the same Rogerstone design purchase at a later time?
Absolutely! Repeat orders use the original artwork file, which means you can increase an order or repeat it for a new season without redesigning the packaging from scratch.
Request a without charge quote from Custom Pack Studio now.
Share your product, packaging requirements and anticipated quantities by calling 01294 314 919 or emailing contact@custompackstudio.co.uk.
We set no minimum order. Every project provides design support, and every item of custom packaging we produce here is designed around your product, not a template.
Begin your enquiry, and we will respond with a written quotation.
