Rigid Setup Boxes

Rigid setup boxes from paperboard (100% recycled materials)

Custom setup boxes are the high-end style preferred by quality retailers and manufacturers trying to promote their brand and image by using package commensurate with the quality and value of their product.

Rigid boxes, available in any size or configuration with choices for board weights and finishes – interior color stains are available for larger quantity orders, white vat is a standard as well as plain chip. Interiors may also be lined with gloss or matte colored papers. Board weight, referred to as “caliper” is represented in thousands of 1”. For example a standard board weight for small boxes is .036.  .048 is a medium weight and .060 is a premium weight. Beyond .060 boards are laminated together for increased thickness and strength (calipers like .080 and .125 are typical of “pasted board”.)

Setup boxes are typically grouped in catagories like: jewelry boxes, hat boxes, gift boxes, cardboard boxes, etc. There are standard sizes in each of these catagories where dies and tooling exist for these to be customized in terms of coverings without incurring additional costs that would be associated with custom sizes. Coverings include preprinted custom offset printed sheets (signature papers), smooth or embossed roll papers, latex coated papers, and some bookbinding materials (cloths). Matte and gloss laminated papers may also be available to cover set-up boxes.

Typically rigid setup boxes, whether machine made or hand made, are available in smaller quantities than folding boxes of similar size. Typically with much shorter lead times.

Rigid boxes are available in a variety of shapes: Rectangles, Squares, Rounds, Ovals, Octagon and Heart shapes. Paperboard platforms and die cuts are available to go into these boxes as well as thermoformed trays in colors or flocked as well as die cut foams in a variety on densities and toppings for most any application.

Plain “stayed boxes” are available in squares or rectangles with either tan or white stay tape and metal stays are also available for decoration and strength.

Sleeves or “packers” are available for high end boxes for protection and ease in gift wrapping.

Generally set-up boxes are two-piece (a top and a bottom) either fully-telescoped or semi-telescoped (short lid). For up-scale products 3 piece set-up boxes make an impressive presentation with a collar or cuff inserted into the base. There three pieces boxes may be hinged with paper, cloth or metal. Using a narrow top and bottom with a deeper collar in a contrasting color or material gives the box a “reveal” that makes for a signature look.

With “post-printing” exterior wraps may be hot stamped (debossed) or raise embossed with combination dies. These processes are generally used for high end copy or smaller quantities with stock papers. Unique borders, side printing and mix-match colors can be incorporated into the design of any set-up rigid box.

Where space and freight are considerations – high end boxes are available with set-up lids and folding bottoms. These combination boxes offer unique design opportunities with considerable savings and have been adopted by many high end retailers with multiple locations. Sleeve and tray (matchbook style) can be a combination of board weight and covering materials. Rigid set-up “trays” also lend themselves to clear acetate lids with inside or outside fit depending on quantity and the item to be packaged.