custom printed mailing boxes with inside print

The Process of Creating Custom Printed Mailing Boxes

Custom printed mailing boxes have become a crucial component of modern packaging strategies. Brands across various industries are leveraging the power of custom packaging to enhance brand identity, create memorable unboxing experiences, and stand out in the competitive market. However, the journey of creating custom printed mailing boxes involves a systematic and intricate process that goes beyond mere design and printing. In this article, we will take a comprehensive look at the step-by-step process of creating these personalised packaging solutions, from conceptualisation to final delivery.

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Step 1: Conceptualisation and Design

The first stage in the process of creating custom printed mailing boxes begins with conceptualisation and design. Here, the brand collaborates with packaging designers or creative agencies to define the objectives, target audience, and brand identity they wish to portray through the packaging. Designers explore various ideas, considering the brand’s logo, colours, and messaging to create visually appealing and cohesive packaging designs that align with the brand’s vision.

Advanced design software is utilised to create digital mock-ups, allowing brands to visualize the final product before manufacturing. During this stage, iterative feedback loops between the brand and designers ensure that the packaging design truly reflects the brand’s personality and resonates with the intended audience.

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Step 2: Material Selection

Once the packaging design is approved, the next step is material selection. Custom printed mailing boxes can be made from various materials, including corrugated cardboard, paperboard, and eco-friendly options like recycled or biodegradable materials. Brands must consider factors such as product weight, protection requirements, budget constraints, and sustainability goals when choosing the appropriate material for their custom packaging.


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Step 3: Printing and Production

With the design and materials finalised, the custom printed mailing boxes move into the production phase. Sophisticated printing techniques like offset printing, flexography, or digital printing are employed to ensure high-quality results and vivid colours. Brands have the option to use spot colours, metallic foils, embossing, or debossing to add an extra layer of luxury and elegance to their packaging.

The production process involves converting the selected materials into the desired box shapes and sizes. State-of-the-art die-cutting machinery ensures precise cuts, folds, and creases, resulting in perfectly formed custom boxes.


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Step 4: Quality Control and Testing

During production, rigorous quality control measures are in place to maintain consistency and meet the brand’s standards. Sample boxes are tested for durability, print quality, and structural integrity to ensure that the final product meets the desired specifications.

tissue paper in box

Step 5: Finishing Touches

Custom printed mailing boxes often receive finishing touches to elevate their appearance. This can include adding inserts, tissue paper, custom stickers, or ribbon to enhance the unboxing experience further. Brands may also incorporate special features like tear strips or resealable closures for added convenience and functionality.

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Step 6: Packaging and Shipping

Once the custom printed mailing boxes are ready, they are carefully packaged and shipped to the brand’s fulfilment centers or directly to customers. Brands can opt for bulk shipments to save on costs or utilise print-on-demand services for smaller quantities and more flexible inventory management.


The process of creating custom printed mailing boxes involves a meticulous journey from conceptualisation to delivery. Brands invest significant time, effort, and creativity to ensure that their packaging aligns with their brand identity, resonates with their audience, and enhances the overall customer experience.

With attention to detail at every stage of the process, custom printed mailing boxes become powerful marketing assets that not only protect products but also convey brand values, create lasting impressions, and foster brand loyalty. By understanding and optimising this process, brands can leverage custom packaging as a strategic tool to elevate their brand, gain a competitive edge, and connect with their customers in meaningful and memorable ways.

Get In Touch

If you would like to get your own custom mailing boxes then get in touch and our experts at Comet Packaging will be happy to help.