Custom Packaging Boxes | Rigid Cardboard Mailers for E-commerce Brands
Custom printed packaging boxes by Aorai Pack, crafted from durable rigid cardboard and corrugated materials for secure e-commerce shipping, luxury retail, and product presentation.
Key Features
7days
100pieces
Product Details
Look, most people think a box is just a box. But in our 37 years of manufacturing, we've seen exactly what happens when a brand treats packaging as an afterthought. Returns go up. Unboxing videos? Non-existent.
Custom packaging boxes by Aorai Pack aren't just containers. They're the first physical touchpoint your customer has with your brand. We build boxes that actually hold up in real life, protecting your product while making your brand look like a million bucks.
Key Features
Crush-Resistant Fluting: We typically use E-flute for retail and B-flute for heavier items. It's about 25% thinner than standard cardboard but holds up to roughly 30% more stacking pressure.
High-Fidelity Printing: Full CMYK offset or digital. We hold color tolerance within a 3% Delta E. It's tight, but it keeps your brand colors looking exactly like they do on screen.
Eco-Certified Materials: FSC-certified papers are available. Fair warning, though—going 100% recycled usually adds about 10-15% to the material cost, but your customers will definitely notice.
Custom Die-Cut Inserts: Cardboard or EVA foam. We design them to hold your product snugly. No more rattling around during transit.
Premium Finishes: Spot UV, soft-touch lamination, or hot foil stamping. Spot UV looks incredible, but here's a heads-up: it can crack if the box is scored too aggressively during folding.
Flat-Pack Efficiency: Most of our mailers ship flat. This cuts your inbound freight costs by roughly 40% compared to pre-assembled rigid boxes.
Product Parameters
Material: 350gsm Corrugated E-flute
Size: 200x150x80mm / Custom sizes available
Finish: Full-color offset printing + Matte lamination
MOQ: 300 pcs
Lead Time: 10-15 working days
Product Details
1. Custom Specification Options
There's no one-size-fits-all here. If you're shipping heavy ceramics, we usually recommend B-flute corrugated. For cosmetics or jewelry? Rigid board is the way to go, though it does bump up the unit cost by about $0.20 to $0.50 per piece.
You can choose from kraft, white card, or black core materials. Printing crafts range from standard 4-color process to Pantone spot colors. Need accessories? We can add magnetic closures, ribbon pulls, or custom tissue paper. Just keep in mind that every extra component adds roughly 2-3 days to the production timeline.
2. Usage Scenes
Where do these boxes actually shine? Here's what we've noticed from our client data:
✅ E-commerce & DTC Brands: Perfect for apparel, electronics, and subscription boxes. The sturdy walls prevent transit damage.
✅ Luxury Retail: Rigid boxes with soft-touch lamination give high-end perfumes and watches that premium feel.
✅ Food & Beverage: We use food-grade inks and materials for bakery boxes and chocolate packaging.
✅ Corporate Gifting: Great for holiday gifts and onboarding kits. We can even add custom foam inserts for multiple items.
3. Factory & Qualification Advantages
We aren't a trading company. We're a 37-year-old manufacturing facility. That means you're dealing directly with the people running the machines. We're ISO 9001 certified for quality management and FSC certified for sustainable forestry. When you order from us, you get global shipping capabilities with direct factory pricing.
FAQs
Can I get a physical sample before committing to a full run?
Absolutely. We highly recommend it. A custom sample takes about 5-7 days to produce and usually costs between $50 and $100 depending on the complexity. We'll deduct this cost from your final bulk order.
What's the actual difference between E-flute and B-flute?
Thickness and crush resistance. E-flute is thinner (about 1.5mm) and takes print much better, making it ideal for retail boxes. B-flute is thicker (around 3mm) and offers better cushioning for heavier, fragile items.
Do you offer graphic design services?
We can help with structural design and layout adjustments, but we aren't a creative agency. If you need a brand-new logo or complex illustrations, you'll need to bring your own designer. We just need print-ready vector files.
How much does custom die-cut tooling cost?
For a standard box shape, we often don't charge for the die. If you need a completely custom shape, the tooling fee is usually around $100 to $150. It's a one-time charge.
Can I order less than 300 pieces?
Honestly, for 50 boxes, you're better off using a local shop. Our minimum for offset printing is 300. We can do 100 pieces using digital printing, but the unit price will jump significantly.
What file format do you need for the artwork?
We need AI, EPS, or high-res PDF files. Make sure all text is outlined and images are at least 300 DPI. If you're using spot colors, please specify the exact Pantone codes.
How do you ensure color matching?
We print to Pantone standards, but remember that paper absorbs ink. A matte uncoated paper will make colors look slightly duller than a glossy coated sheet. We always do a digital proof first to get you in the ballpark.
Do you ship internationally?
Yes, we ship globally. We can do FOB, CIF, or DDP. To the US West Coast, sea freight takes about 18-22 days. Air freight cuts it to 5-7 days, but it'll cost you roughly three times as much.
What's the maximum box size you can produce?
Our largest printing press handles sheets up to 1040x740mm. Practically speaking, we can make boxes up to about 60x40x40cm. Anything larger than that requires specialized structural engineering.
How should I store the boxes when they arrive?
Keep them in a cool, dry place. Cardboard is hygroscopic, meaning it absorbs moisture. If you store them in a damp warehouse, they'll lose their structural integrity and the printing might get damaged.
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