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Barton Jones Packaging Ltd
Industry solutions

Packaging for subscription and direct-to-consumer brands

Branded, repeatable packs for subscription boxes and DTC brands, right-sized for postal rates and built to survive an unattended doorstep.

The problem

What usually goes wrong

Subscription brands live and die on two numbers: cost per despatch and the moment the customer opens the box. Most stock packaging is bad at both.

A box that is a few millimetres too tall misses a letterbox rate and moves every despatch into a higher postal band, every month, forever.

And because the pack repeats monthly, any weakness compounds: a fiddly closure costs the same extra seconds on every single order.

Typical pack

Packaging components we usually specify

  • Printed die-cut mailers sized to your monthly contents
  • Letterbox-friendly formats where depth decides the postal rate
  • Printed tape and branded outers for a consistent unboxing
  • Paper void fill and Paperwave air cushions for plastic-free filling
  • Inserts, dividers and trays to fix the presentation inside the box
  • Kitted packs with cards and inserts pre-assembled

Materials

Relevant materials and board grades

  • E flute (approx. 1.5mm) for a sharp print face on customer-facing mailers
  • B flute for slim, strong shipping formats
  • EB double wall for premium packs that still need a clean face
  • Paper tapes, paper mailers and paper void fill for plastic-free despatch
  • FSC certified board under licence C214479 for your sustainability claims

In-house

Our manufacturing and assembly capabilities

  • Bespoke die-cut sizes made in-house with no tooling charge, so depth can be tuned to a postal band
  • Printed boxes and printed tape carrying your brand properly
  • Prototype and sample before a launch, so nothing is committed on a guess
  • Assembly and kitting so monthly packs arrive part-built
  • Short runs for a launch, scaling as subscriber numbers grow

Stock holding

How we hold stock for you

  • Hold your standard mailer at volume price and call off monthly against subscriber numbers
  • Space freed for product rather than flat-packed board
  • Scheduled deliveries timed around your despatch window

Accreditations

Relevant accreditations for this sector

  • FSC C214479
  • BRCGS Storage & Distribution
  • Verified Carbon Standard
See our accreditations and request the literature

Real example

Ten millimetres that changed the postage bill

A subscription brand was shipping in a stock mailer that sat just over the depth limit for the cheaper postal band, on every despatch, every month.

We designed a printed die-cut mailer ten millimetres shallower with a fitted insert that held the contents in place at the reduced depth.

The whole subscriber base moved into the lower band, the pack presents far better on opening, and the saving on postage more than covered the difference in the box.

Sector enquiry

Tell us your postal band target

Send your current mailer dimensions, monthly volume and the postal band you want to hit. We will design a printed pack to fit it.

  • Current box size and contents
  • Postal band or courier rate you are aiming for
  • Print and branding requirements
  • Monthly despatch volume and growth expectation
Use the enquiry form01462 680888

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