A generic box leaves gaps around the product inside it, so it rattles in transit until someone stuffs the space with foam or paper to stop it moving.
Off-the-shelf packaging with a sticker on the side is the easy option, but it’s built for nobody in particular.
Custom Pack Studio makes bespoke packaging around your product instead, so the box, the print and the finish work for your brand rather than sitting on top of it.
We manufacture custom boxes, mailer boxes, gift packaging and printed accessories for businesses across Wales, from Cardiff and Swansea to Newport and the valleys beyond, and order sizes range from a single sample to a pallet load delivered straight to a warehouse door.
There’s no minimum order on anything we produce, which keeps stock and storage costs off the table until you know a product sells. Tell us your packaging requirements and we’ll size the recommendation to the product itself.
What custom packaging means
Custom packaging means the box is drawn around your product from the start: the size and the print both follow what you’re packing.
You choose the dimensions, so a custom sized box holds the product snugly instead of rattling around inside extra space left by a generic size.
The structure, the board weight, the print and the finish are custom designed too, matched to what’s being packed and how it travels.
A logo printed onto a stock box is personalised packaging, a smaller job than fully customisable design.
With customised packaging, every panel, fold and finish is open to change, even on a run of one, so you create custom packaging that fits without compromise.
Packaging formats we make for Welsh businesses
We produce a full range of packaging boxes, all made to bespoke sizes and printed in full colour with your artwork.
The right box style, and the right type of packaging generally, depends on what you’re selling and how it’s handled, and our packaging experts will talk you through the options.
Retail cartons and branded packaging
Reverse tuck-end cartons are a retail packaging staple, suiting lighter items such as cosmetics and supplements, with flaps that tuck in at the top and bottom.
Crash-lock boxes are a type of lock box, a sturdier style of cardboard boxes with a base that snaps flat as you open it, so heavier products don’t push the bottom out.
Mailer and e-commerce boxes
A custom mailer box protects your product through the courier network and turns delivery into part of the brand experience and brand visibility, since it’s printed inside and out rather than just on the outer face.
Gusseted versions of these custom printed boxes add depth for bulkier items that need room to sit without shifting.
Gift boxes, rigid boxes and gable boxes
Rigid boxes, magnetic-close gift boxes and other branded boxes give products bought as presents the kind of presentation a customer expects without wrapping anything themselves.
Gable boxes, the type with a fold-up carry handle, work well for food gifts and hampers.
For premium ranges we sometimes specify SBS board (solid bleached sulphate, a bright, food-safe paperboard) instead of standard carton stock, and finishes like foil and soft-touch lamination add to the effect.
Design support for your brand
Packaging design support is available with every order, whatever stage your artwork is at.
If you’ve got a logo and brand guidelines, our design experts prepare print-ready files and check the colours hold up on board, since packaging needs a higher resolution than a website image.
You don’t need previous design experience to create packaging that fits your brand. Our team can start from just a logo. They work out the structure and the expertly designed, print-ready artwork with you, and talk you through the technical choices as they come up.
Our online tool also lets you personalise a box and see the look and feel on screen before anything goes to print, and we offer Pantone colour matching so a repeat order stays consistent.
If you want packaging printed bilingually in English and Welsh, our team treats that as a standard artwork requirement, handled the same way as any other language or colour change.
Custom packaging for Wales’s industries
Food and drink
Welsh Lamb and Welsh Beef both carry Protected Geographical Indication status, and any food packaging touching meat or dairy has to meet food-contact standards regardless of which side of the border it’s made.
We hold BRC Global Packaging certification at High Hygiene level, so our food packaging is produced under controlled, traceable conditions that retailers check before listing a product.
Drinks and distilleries
Wales has built a genuine drinks scene over the last two decades, from Penderyn in the Brecon Beacons to newer gin and whisky producers further north.
Presentation boxes for bottles need to survive transit and still look right on a shelf, and finishes such as foil stamping and embossing do most of that work for a limited release or a seasonal gift set.
Cosmetics and beauty
Cosmetic and skincare brands need cartons that protect fragile glass and compacts while looking right on a shelf.
We print cosmetics packaging with soft-touch lamination, foil and embossing, and rigid boxes suit a premium range that needs to justify a higher price point.
E-commerce and subscription brands
Retail-ready and display packaging matters when a product sits in a shop or a marketplace fulfilment centre, but subscription brands face a different test. The same customer opens a near-identical box every month, so a consistent finish matters as much as the original design.
Good e-commerce packaging, cut to the exact size of your product packaging, keeps items steady through the post and cuts damage claims and returns.
A fitted insert or printed tissue keeps the product from moving in transit, and the print stays visible the moment the box is opened.
For a subscription brand reordering every month, using the same box dimensions each time keeps pallet space and warehouse racking predictable, which matters more once volumes grow past a few hundred units.
Delivering to Wales from our Scotland factory
Everything is manufactured at our facility in Irvine, Ayrshire, with UK delivery to businesses across Wales as standard, from Cardiff, Swansea and the rest of South Wales to Wrexham in the north.
Most orders reach a Welsh address within two to three weeks of proof approval, on the same schedule as the rest of our packaging UK-wide.
Custom Pack Studio is part of KennedySmith (Press) Ltd, a packaging manufacturer producing print and packaging since 1997, so an established team makes the boxes on their own presses.
You see a proof, and a physical sample where the format needs one, before anything goes into full production, and reorders use the same artwork so scaling up doesn’t mean starting again.
Working with one box company for packaging across your whole product line keeps things simple.
You deal with one invoice and one point of contact, instead of chasing several suppliers who each quote a different price for a different week.
Sustainable packaging as standard
Every box we make is 100% recyclable, and that recyclability comes from the board itself.
Our board and paper come from FSC and PEFC certified sources, tracing every sheet through an audited supply chain back to responsibly managed forests.
We’re cutting single-use plastic and EPS foam void fill across our processes, since neither recycles easily and both create disposal problems once a parcel’s been opened. Where a design allows for it, biodegradable or paper-based protection replaces them instead.
No minimum order for Welsh businesses
Custom packaging usually carries minimum order quantities of 500 or 1,000 units elsewhere in the industry, which means paying for stock and storage before you know whether a product sells.
We set no minimum order at all.
Small businesses can order a single sample, small runs for a trial, or a full production run once demand is proven, and pricing scales per unit at every quantity along that range.
You always get a written quote before production starts, and the high-quality materials and packaging products you receive at a run of fifty are the same as a run of ten thousand.
Before committing to volume, request a printed sample and check the print, the colour and the fit in your hand.
How to order custom packaging
- Share your brief – Call 01294 314 919 or use the online design tool, and tell us the product, the quantity, and roughly how it’s sold.
- Design and proof – We work out the packaging design that fits your product, lay out the print, and send a proof for you to check.
- Sample and approve – Request a physical sample if the format needs one, then sign off once you’re happy with the colour and construction.
- Production and delivery – Your order is printed and finished in Irvine and delivered to your Welsh address, usually within two to three weeks.
Custom packaging Wales FAQ
Do you deliver custom packaging to Wales?
Yes. We manufacture everything in Irvine and deliver across the UK as standard, including every part of Wales from Cardiff and Newport to Swansea and further north, with no separate charge just for being further from the factory.
What is the minimum order for packaging in Wales?
There isn’t one. You can order a single box or several thousand on any format, and pricing scales with quantity from a written quote before production begins.
Which parts of the packaging can I customise?
Size, structure, board weight, print and finish are all open to change on every format, so the designed packaging matches your brief exactly. A branded packaging order can be printed on the inside as well as the outside too.
Can you send samples of your packaging products before I order?
Yes. A sample arrives printed and finished exactly like a production run, so you can confirm the colours match your brief and the board feels right before signing off a bulk order.
Is the packaging recyclable and can it be biodegradable?
Every box is 100% recyclable. We avoid plastic laminates that would stop recycling unless food safety requires them, and biodegradable protective materials are available where the format allows it.
Can I reorder the same design later?
Yes, reorders run from the same artwork file, so growing an order or repeating one for a new season doesn’t mean redesigning the packaging from scratch.
Request a free quote from Custom Pack Studio today
Call 01294 314 919 or email contact@custompackstudio.co.uk with your product, your packaging needs and the quantities you have in mind.
There’s no minimum order, design support is built into every project, and every piece of custom packaging made here starts from your product rather than a template.
Start your enquiry and we’ll come back with a written quote.
