Everything You Should Know Before Ordering Your Product Packaging

Packaging is essential for product presentation, protection, and branding, playing a vital role in the food, cosmetics, retail, and pharmaceutical industries. Product packaging serves multiple functions, including protecting products, enhancing brand identity, helping transport and storage, and conveying important information through labeling. Packaging has evolved from natural materials like leaves and clay to modern eco-friendly designs, meeting the needs of businesses and consumers.

Packaging types are categorized by material (paper, plastic, glass, metal, wood), usage (custom, sustainable, flexible, retail, luxury, e-commerce, bulk), and function (primary, secondary, and tertiary). Packaging can be either custom or stock, depending on the specific needs of a brand, product, or business. Custom packaging is designed specifically for a product or brand, allowing for unique sizes, shapes, materials, and branding elements like logos, colors, and custom prints, while stock (pre-made) packaging offers a practical solution for general use at lower costs.

The packaging development process includes material selection, design refinement, durability testing, and supplier collaboration to ensure functionality and cost efficiency. Ordering custom packaging requires understanding your product’s needs, setting a budget, choosing suitable materials, designing the packaging, and selecting a reliable supplier.

Packaging is the science, art, and technology of containing, protecting, and presenting items for marketing, storage, shipping, and use. Packaging is made of various materials such as paper, cardboard, plastic, glass, metal, or biodegradable substances, chosen based on the product’s specific requirements. Packaging is widely used across industries such as food, pharmaceuticals, electronics, and retail to enhance brand identity, protect products, preserve them, facilitate transportation and storage, and communicate essential information through labeling.

The history of packaging began in ancient times, with natural materials like leaves, clay, and animal skins being used for storing and carrying goods. The Chinese wrapped food with treated mulberry bark in the 1st century BC. Peter Durand invented the tin can in 1810, which enabled long-term food storage. Paper bags became commercially available in 1844, and in 1852, Francis Wolle invented the first automatic machine to make paper bags, making them more accessible and practical.

The development of printing technologies played a crucial role in the evolution of packaging. The earliest forms of printing on packaging can be traced back to the 15th century with the invention of the printing press, which allowed basic text and images to be applied to paper wrappers. By the 19th century, lithographic printing introduced vibrant, multicolored designs to packaging, greatly improving product branding and increasing consumer appeal.

In the 20th century, cellophane (introduced in 1900) and plastics revolutionized packaging, making it lighter, more flexible, and easier to print on. Techniques like offset printing, flexography, and gravure printing emerged, allowing for detailed and durable designs on various materials, including cardboard, metal, and plastics. In the late 20th century, screen printing and digital printing enabled the creation of custom-printed packaging designs.

In 1952, Michigan State University started the first degree program in Packaging Engineering, showing its importance in modern industries. Today, packaging focuses on sustainability, with innovations such as recyclable and biodegradable materials designed to reduce waste.

Packaging serves multiple purposes, including marketing, branding, protecting, containing, preserving, transporting, and communicating, all while playing a vital role in the product’s usability and market appeal.

1. Branding: Packaging establishes and communicates the product’s identity through the use of logos, colors, and designs. It also promotes brand recognition and loyalty by creating a distinct and memorable presence for consumers.
2. Marketing: Packaging is used to attract buyers with visually appealing designs, effective messaging, and unique features. It influences purchase decisions and helps products stand out from competitors in a crowded market.
3. Protection: Packaging protects the product from damage, contamination, and external factors like moisture, light, and temperature changes during storage, transportation, and handling.
4. Containment: Packaging is used to hold the product, especially liquids, powders, and small items, for safe storage and shipping.
5. Preservation: Packaging keeps the product fresh, safe, and intact throughout its shelf life by preventing spoilage or degradation.
6. Shipping: Packaging ensures the safe and efficient transportation of products by protecting them from damage and keeping them organized for smooth handling during transit.
7. Information Transmission: Packaging provides essential details like ingredients, usage instructions, safety warnings, expiration dates, and recycling guidelines, helping consumers make informed decisions.
8. Convenience: Packaging simplifies handling, transport, and storage for both businesses and customers, making the product easy to use.

Packaging promotes, protects, preserves, transports, and informs, while enhancing usability and supporting sustainability, making it essential for both businesses and consumers.

Labeling in packaging involves providing printed or graphic information on a container or article to communicate essential details about the product. Package labeling serves multiple purposes, including identifying the product, informing customers, and ensuring compliance with legal requirements. Package labels include details such as the product name, brand, ingredients, usage instructions, safety warnings, and expiration dates. These labels also feature barcodes, lot numbers, and recycling or handling symbols. Clear and accurate package labeling helps consumers make informed decisions, builds trust, and reinforces the brand’s identity. Labels play a vital role in packaging by enhancing functionality and appeal.

Packaging types are divided into three categories based on material, usage, and function. The materials include paper, plastic, glass, metal, and wood. Paper-based packaging such as cardboard, paperboard, kraft paper, card stock, and corrugated fiberboard is widely used in food, retail, and e-commerce industries. Packaging made from paper-based materials is eco-friendly, recyclable, and easily customizable for branding. Plastic is lightweight and versatile, often used for bottles and containers. Glass provides a premium look to the packaging, making it ideal for beverages and perfumes. Metal provides durability and protection, commonly used in cans and tins. Wood is primarily used for crates and pallets in shipping.

Packaging types based on usage include custom packaging, sustainable packaging, flexible packaging, retail packaging, luxury packaging, e-commerce packaging, and bulk packaging. Custom packaging is made to fit a specific brand or product. Sustainable packaging incorporates eco-friendly materials such as recycled or biodegradable components. Flexible packaging is lightweight and easy to shape, often used for food. Retail packaging is designed to look attractive in stores, while luxury packaging uses high-quality materials for a premium feel. E-commerce packaging ensures product protection during shipping and enhances the unboxing experience. Bulk packaging is used to transport large quantities of goods safely.
Packaging can be categorized into three types based on function such as primary, secondary, and tertiary packaging.

Primary, secondary, and tertiary packaging are three layers of packaging based on their function to contain, protect, store, display, and transport products.

1. Primary Packaging: Primary packaging directly holds and protects the product, ensuring safety and usability. Examples of primary packaging include bottles, cans, jars, pouches, tubes, wrappers, and blister packs.
2. Secondary Packaging: Secondary packaging is used to group primary packages to facilitate handling, storage, distribution, or display. Secondary packaging includes cardboard boxes, shrink wrap, and mailing bags.
3. Tertiary Packaging: Tertiary packaging is used for bulk handling, warehouse storage, and shipping to ensure safe and efficient transportation. Examples of tertiary packaging include pallets, stretch wraps, and shipping containers.

Custom packaging is a type of packaging that is produced in the desired design, shape, material, and style to pack, store, and ship products like food, cosmetics, candles, and safely while promoting the brand.

Stock packaging is pre-made, generic packaging that offers standard sizes, limited customization, lower costs, and quick availability, making it ideal for basic needs and quick shipping. Custom packaging is designed specifically for a product, offering custom designs, styles, materials, sizes, and branding elements like logos and colors, creating a more premium and memorable customer experience. Stock packaging is ideal for startups, test marketing, or general shipping, while custom packaging is preferable for luxury goods, unique items, or businesses prioritizing branding and customer impressions.

The packaging development process begins by identifying product requirements, such as size, durability, and regulatory compliance. This is followed by market research to analyze trends, sustainability, and consumer preferences. An initial design concept is created and refined based on stakeholder feedback before being evaluated for cost-effectiveness.

The next step involves selecting the right packaging material, considering factors like durability, sustainability, and logistics. A reliable supplier is chosen, and a final design mock-up is produced for approval. Finally, durability and performance tests confirm its effectiveness before full-scale production begins, incorporating strict quality control measures.

An eleven-step process for packaging development is given below:

1. Identify Product Requirements
2. Research and Analyze Market Trends
3. Develop Initial Design Concept
4. Approve Packaging Design Concept
5. Analyze the Cost of Packaging
6. Choose the Right Packaging Material
7. Select a Reliable Packaging Supplier
8. Create a Final Design Mock-Up
9. Test and Approve Packaging
10. Initiate Production and Quality Control
11. Audit and Approve Packaging

Packaging costs can range from as little as $0.10 to hundreds of dollars per unit. The cost of packaging depends on various factors, including box size, material, artwork design, printing techniques, and finishing options.

Packaging improves product marketing by creating strong first impressions, attracting customer attention, and differentiating products from competitors. Custom packaging communicates a brand’s identity through consistent use of logos, colors, and typography, while also highlighting product benefits and features. Functional packaging enhances customer experiences with practical features such as resealable, easy-to-open designs and convenient elements like easy-pour spouts or handles, which add value and differentiate brands. According to a European Journal of Marketing study from the Marketing and Innovation Department, functional packaging increases purchase intentions by enhancing product meaningfulness and creating a strong first impression, especially for low-complex products. Eco-friendly packaging, made from recyclable or biodegradable materials, reduces waste and appeals to environmentally conscious consumers. Interactive packaging engages customers with promotional elements like QR codes or special offers. Effective product packaging boosts sales, strengthens brand loyalty, and increases brand awareness by incorporating functional features, sustainable materials, and engaging design elements.

Packaging increases brand awareness by making products easily recognizable through consistent use of logos, colors, designs, typography, and images. According to research from the Design Department at Southern New Hampshire University, Color enhances brand recognition by up to 80%, highlighting how a strong visual identity improves brand recall. Eye-catching packaging captures attention, reflects brand values, builds trust, and helps customers connect emotionally with the brand. Custom packaging serves as a visual representation of the brand, maintains a consistent look across products, makes it easier for consumers to recognize and remember the brand, encourages loyalty, and stands out in stores. According to Pennsylvania State University research from the Department of Consumer Psychology, brand image conveyed through packaging plays a crucial role in shaping consumer perception of product quality and influencing purchasing decisions.

Packaging design is crucial for products as it effectively communicates their benefits, attracts buyers with eye-catching visuals, and enhances functional usability. According to a study conducted by the Paper and Packaging Board and IPSOS, 72% of American consumers state that the design of a product’s packaging often influences their purchase decisions. Well-designed packaging improves the overall consumer experience and strengthens brand identity.

The role of a packaging designer in packaging is to create visually appealing and functional designs that align with brand identity and product requirements. Packaging designers develop designs that attract consumers, communicate essential information, and meet practical needs like durability and usability.

The packaging engineer creates structural packaging by designing and testing materials and structures to ensure product safety, usability, and cost-efficiency. Packaging engineers analyze the product’s characteristics, transportation requirements, and environmental impact to design a package structure using appropriate materials like corrugated cardboard and strategically incorporate features like folds, creases, and reinforcements.

Packaging companies that primarily offer stock or pre-made packaging for products are listed below.

• Uline
• Amcor
• WestRock
• Ball Corporation
• Berry Global
• Sealed Air
• Crown Holdings
• Sonoco

These packaging companies provide standard packaging such as boxes, bags, wraps, and containers that are pre-made and designed to meet general requirements. However, they do not offer customization for specific branding or design needs. In contrast, Packhit specializes in custom packaging, enabling businesses to create product packaging tailored to their brand, design, material, and style requirements.

To order custom packaging for your products, you need to assess your product’s dimensions and requirements, set a budget by calculating material and design costs, choose suitable packaging and materials, determine box dimensions and style, design the packaging, select printing and finishing options, and partner with a reliable packaging supplier.

Follow the steps given below to order custom packaging for your products.

1. Understand Your Packaging Needs
2. Estimate Your Packaging Budget
3. Select the Type of Packaging
4. Measure Box Dimensions for Product Packaging
5. Choose the Right Material for Your Packaging
6. Look for Sustainable Packaging Materials
7. Select the Box Style for Your Packaging
8. Create the Design of the Packaging
9. Choose the Appropriate Printing Option for Your Packaging
10. Select the Add-ons and Finishes
11. Find a Trusted Packaging Supplier

Begin by assessing your product’s dimensions, weight, and specific requirements for storage, marketing, shipping, and protection. Identify your branding goals and the functional features needed to ensure that your packaging aligns with your target audience’s expectations.

Calculate your packaging costs by factoring in material type, design complexity, order quantity, and printing options. Determine the cost per unit to ensure it stays within your budget constraints.

Choose the appropriate packaging type such as boxes, pouches, tubes, or wrappers based on your product’s size and intended use. For example, fragile products may require durable materials for protection, while retail products benefit from visually appealing options like display boxes.

To accurately measure box dimensions for product packaging, measure the length (L), width (W), and height (H) of the box using a ruler or measuring tape, considering both internal and external dimensions. Record the measurements in L × W × H format in inches or centimeters, double-check for accuracy, and account for additional packaging needs such as protective materials, flaps, and weight restrictions. Accurate box measurements help optimize packaging fit, protection, and shipping efficiency.

Select appropriate packaging materials based on durability, cost, and environmental impact. Common materials for custom packaging include cardboard, paperboard, corrugated cardboard, kraft paper, card stock, and rigid.

Opt for eco-friendly materials such as cardboard, recycled paper, or reusable packaging for your product packaging to support sustainability goals and attract environmentally conscious consumers.

Select a box style that best suits your product, such as mailer boxes, display boxes, or tuck end boxes. Ensure the chosen box style aligns with both functionality and branding to enhance product presentation and protection.

Create an eye-catching design incorporating brand elements such as logos, colors, and graphics to enhance customer engagement. Work with a professional designer or submit pre-made artwork to your packaging supplier to create a custom design that reflects your brand identity. 

Selecting the right printing method for your packaging depends on your budget, material, design, and production requirements. Digital printing is great for small batches and fast production, while offset printing provides high-quality images for large orders. Flexographic printing is best for high-speed printing on flexible materials, and screen printing works well for bold designs on rigid surfaces. Gravure printing is ideal for large-scale, high-quality prints. Choosing the right printing method ensures your packaging is visually appealing and functional.

Select finishes like coatings, laminations, foil stamping, embossing, debossing, and spot UV coating to enhance the visual appeal of the product packaging.

Incorporate additional features such as foam inserts, cardboard dividers, die-cut handles, magnetic closures, ribbon closures, window cutouts, custom inserts, QR codes, NFC tags, security seals, and tamper-proof features to enhance functionality, security, and user experience.

Partner with a reliable packaging supplier to produce high-quality custom packaging in the required quantities within your timeline and budget. Verify their experience and customer reviews to ensure reliability.