The Cost of Custom Packaging: What Affects Pricing and How to Save

Why Custom Packaging Matters

Before we get to numbers, let’s briefly discuss why spending on custom packaging is worth it.

It’s not just about looks—it’s about experience.

• Enhances brand recall
• Boosts customer satisfaction
• Boosts social shares and repeat purchases
• Degradates products less
• Lets you stand out

Now let’s look at what influences the price of custom packaging.

1. Packaging material

This is one of the biggest cost drivers.

Different materials have different price points, depending on durability, appearance, sustainability, and availability.

Typical Packaging Materials:

2. Printing Processes

Printing adds personality to your packaging—but it also costs money.

Printing Type:

They all leave a different impression. Digital is cheap and fast; foil and emboss are expensive but make brand image.

One-color print on kraft paper to stay affordable without losing eco-chic appearance.

3. Packaging Type and Structure

The more complex your packaging structure, the more its cost of production, assembly, and shipping.

Types of Packaging (from simplest to most expensive):

• Flat mailer envelopes
• Tuck-top boxes
• Two-piece rigid boxes
• Magnetic flap boxes
• Die-cut window boxes
• Trays and inserts by designer

Mass-produced standard box sizes are cheaper than die-cut shapes or custom-cut shapes. And simple folds are cheaper (and quicker) to assemble than intricate designs.

Design using standard box styles like mailer boxes or tuck-end boxes to minimize expensive tooling or mold costs.

4. MOQs (Volume of Orders)

This greatly impacts unit price per.

How Volume Affects Cost

• Under 100 units: Too expensive per box (e.g., $2–$5+ per unit)
• 500–1,000 units: Improved prices (~$1–$2 per box)
• 5,000+ units: Lowest prices (as low as $0.50/box depending on material)

This is because of setup fees in printing and tooling. After those are funded, more units = lower cost per-piece.

When you are starting out, look for low MOQ custom packaging manufacturers. You may pay more per unit, but you’re not investing in monster initial investment.

5. Shipping, Storage, and Assembly

Most brands ignore the shipping cost of packaging:

• Heavy products = higher shipping cost
• Large boxes = dimensional weight fees
• Assembled boxes = higher storage need
• Flat-packed boxes = less storage space, cheaper

Also consider whether you’ll have your employees assemble the packaging or whether you’ll be paying for pre-assembly.

Use fold-flat packaging and assemble as necessary to economize on warehouse and freight costs.

How to Save Money on Custom Packaging (Without Looking Cheap)

Now that you know what drives cost, let’s talk about smart ways to save without cutting corners on quality packaging:

1. Value Design Simplicity

• Instead of full-color printing, utilize one or two colors
• Unless strictly necessary, stay away from intricate box shapes
• Stamp printing (cheap but beautiful) is also an option

2. Purchase in Bulk (When Necessary)

Even in the absence of a pressing need for 5,000 units, purchasing in bulk can provide 50% or even higher cost savings in the long run.

Keep extra stocks on hand and use them throughout.

3. Use Standard Sizes

Custom sizes are expensive. Opt for standard box sizes supplied with most suppliers to steer clear of tooling costs.

4. Go Digital

Digital printing with low-volume runs. It’s fast, affordable, and perfect for small business testing.

5. Mix Function and Form

Instead of shipping boxes and gift boxes separately, use mailer boxes that are sturdy and presentable with your brand.

6. Outsource Wisely

Use local vendors to cut international shipping delays and taxes. Compare pricing between freelancers and agencies for design work.

7. Reuse & Recycle Creatively

Use recyclable filler, old wrapping paper styles, or reusable bags that customers love—and will remember.

Real-Life Budgeting Example

Let’s say you’re a handmade soap brand shipping 500 orders/month.

Option A – Premium Setup:

• Rigid box with foil print: $3.50/box
• Custom inserts: $0.80
• Shipping cost: $1.00

Total: $5.30 per order

Option B – Smart Budget Setup:

• 1-color printed Kraft tuck box: $1.10/box
• Recycled filler + thank-you card: $0.40
• Shipping: $0.80

Total: $2.30 per order

Over 500 orders, and you’ve saved $1,500 a month—without losing your branding.

Final Thoughts: Custom Packaging is an Investment, Not an Expense

Your package is not merely a box. It’s your first impression, your brand voice, your customer service, and your silent marketing tool—all in one.

And while customized packaging, or “packaging, customized,” will cost more, clever decisions on material, quantity, and layout can allow you to maintain your financial limits in abeyance while impressing your clients.

Start small. Start smart. But start with intention.