Short-run bespoke boxes: how tooling-free production works

Bespoke cardboard boxes are often associated with large quantities, long lead times and expensive cutting tools. That is not always the case.

What is a short run?

There is no fixed definition. It could mean a handful of boxes for a new product trial or several hundred boxes for a lower-volume production line.

• New product launches
• Prototypes and samples
• Replacement parts
• Seasonal products
• Large or unusual items
• Businesses with limited storage
• Products that change size frequently

Instead of committing to a large quantity before the design has been properly tested, a smaller run allows you to prove the packaging first.

Why do some boxes require tooling?

Traditional die-cut packaging uses a cutting forme containing blades and creasing rules. It is an effective way to produce detailed designs repeatedly, particularly at higher volumes.

However, the tool must be designed and manufactured before production starts. That adds an initial cost and can make a very small order less economical.

Our new GTS Box Master uses vibrating knives to cut different designs directly from sheetboard. Changing from one design to another does not always require a new cutting forme, giving us more flexibility on quantities, sizes and turnaround times.

When is tooling still worthwhile?

Tooling-free production is not automatically the right answer for every box.

A traditional cutting forme may still offer the best unit cost for high-volume repeat orders. Some complex designs may also be better suited to our platen die-cutting equipment.

We consider the design, board grade, quantity and how often the box will be reordered before recommending a production method.

Can short-run boxes be printed?

Printing can also be added to suitable designs. This could include a company logo, product information, handling instructions or basic branding. The best printing method will depend on the design, number of colours and quantity required.

Artwork must always be checked and formally approved before printed boxes are produced. Read our printed cardboard boxes guide for more about artwork and production methods.

Test before committing

A physical sample remains an important part of the process. It allows you to check the fit, strength and packing method using the actual product. Any necessary changes can then be made before the first production run.

Barton Jones Packaging manufactures bespoke boxes at our Letchworth site for businesses across Hertfordshire and the surrounding region.

If you need a short run, unusual size or new design, send us the dimensions, weight, quantity and details of what you are packing. We will recommend the most suitable way to produce it.