Free Packaging Review
A free, no-obligation visit and written review of your packs, materials and process, with samples to test before you commit to anything.
Services
Packaging services: manufacturing, assembly, stock holding and delivery
Thirty years of solving packaging problems for businesses across Hertfordshire and the UK. We manufacture boxes on site, from small bespoke runs to large format boxes, stock the full range of packaging materials and hold stock for you, so you can rely on one supplier for everything.
On this page
We manufacture and supply bespoke packaging throughout Hertfordshire, Bedfordshire, Buckinghamshire, Cambridgeshire, Essex, Northamptonshire and London, on our own vehicles from Letchworth Garden City.
Bespoke Corrugated Box Manufacturing
Your product, your size, your quantity. As a Hertfordshire cardboard box manufacturer we run multiple box-making machines in-house, covering standard box-maker styles, double wall boxes and large format boxes up to 2.8m wide. Running several machines means we can set one up for your job while others keep production moving, so samples and short runs are not stuck behind a single line.
Assembly & Kitting
We manufacture your boxes and assemble them ready for use, so your warehouse team can focus on fulfilment. We also build component sets such as boxes with foam inserts, so you simply place the product inside.
Bespoke Design & Printed Boxes
Send a brief or a sample. We design, prototype and refine the pack until it survives the journey and looks the part. We offer flexographic printing directly and can manage digital and lithographic printing through established specialist partners, remaining your single point of contact throughout.
Packaging Audits
We review your current packs, materials and process to find savings in cost, waste and time, from heavy duty shipping boxes down to tape and void fill.
Stock Holding & Call-Off
Buy at volume, call off as you need it. We typically hold around three months' stock in BRCGS Storage and Distribution certificated storage and deliver on a schedule that suits you.
Transit Packaging & Sustainability Swaps
Stretch film, strapping, pallets and crates for road, sea and air freight, plus practical moves to recyclable and paper-based alternatives without compromising protection.
We regularly deliver packaging into Milton Keynes, Bedford, Luton, Stevenage, Cambridge, Peterborough, Northampton and the surrounding areas. See areas we cover for lead times by postcode.
Manufacturing
See our manufacturing in action
See full details of our in-house capability on our corrugated box manufacturing page.
The difference
How we work, and why customers stay
We design, manufacture, assemble and deliver from our own units in Letchworth, so the same team stays accountable for the whole job.
Design and sampling before you commit
We measure the product, propose a style and board grade, and make you a physical sample so the first production run is right.
A dedicated external and internal account manager
Every customer gets a dedicated external account manager who visits site, sees how the product is packed and reviews the specification with you, plus a dedicated internal account manager in the office who handles quotations, orders, stock call-off and delivery dates. Two named people who know your job, so nothing is lost in a handover and there is always someone available who understands your account.
Same-day manufacturing available
Available on suitable products using available board stock, manufactured on our own line in Letchworth so we control the schedule.
Packaging reviews and cost engineering
We audit what you use now, right-size it and price the alternative, so any change is justified on cost or damage rates.
Certificated and audited
Certified to the BRCGS Storage and Distribution standard and independently audited, plus FSC certificated board (licence C214479) and Verified Carbon Standard, so your own audits are covered.
Assembly and stock holding
Kitting, assembly and call-off stock managed from our own units, so the process stays under one roof.
The design journeyHow a brief becomes a finished, tested pack. Tap to read.
Our process
The design journey, from first conversation to palletised delivery
Every job starts the same way and then splits: a standard pack straight from stock, or a bespoke pack designed around your product. Both routes end with an approved order, manufactured in-house and delivered on your schedule.
Friendly consultation and quote
A straight conversation about your product, volumes and deadlines, followed by a clear written quote.
Product analysis
We look at the product itself, how it's handled and how it travels, so the pack is specified around it.
Standard solution
Standard packaging
Off-the-shelf sizes from stock, plain or with branding added, ready to call off when you need it.
Bespoke solution
Design
Our team draws the die-line around your product, balancing protection, cost and pack efficiency.
CAD sample
A cut sample to test with your real product before anything goes into production.
Branding added
Logo, product details and handling marks applied to the approved design.
Approved, official order
Once the sample and artwork are signed off, the order goes to our production floor.
Manufacturing
Flexographic printing applied directly, with digital and lithographic print managed through specialist partners.
Die-cutting
Cut to the signed-off die-line on our own tooling.
Box making
Standard boxes produced to your exact internal sizes across our box-making machines.
Stitched and glued
Joined for the strength the job needs.
Assembled
Made up ready for use, including component sets.
Palletised and distributed
Wrapped, palletised and delivered on our own vehicles, or held in stock and called off as you need it. Free delivery on orders over £100 within a 30 mile radius of Letchworth.
Board grades explainedFlute types, thicknesses and what each grade is best for.
Board grades
Choosing the right corrugated grade
The flute is the wavy layer between the liners, and it decides how much a box can carry, how well it stacks and how well it prints. If you're not sure which grade suits your product, tell us what you're packing and we'll spec it for you.
E flute
Single wallapprox. 1mm to 1.5mm
A very fine flute with excellent compression strength and crush resistance, plus a high quality surface for printing. Common on smaller cartons and die-cut work where sharp print matters.
B flute
Single wallapprox. 3mm
One of the most widely used grades. Exceptionally versatile and suited to both die-cutting and regular box making, giving good all-round performance across most packaging.
C flute
Single wallapprox. 3.5mm to 4mm
Greater compression strength than B flute, so better stacking strength on lighter products. It can be prone to crushing if used in the wrong application.
EB flute
Double wallapprox. 4mm to 4.5mm · E and B flutes combined
Pairing a very fine flute with a larger one gives an excellent balance of transit protection, strength and print finish. Popular for premium retail packs.
BC flute
Double wallapprox. 6mm to 7mm · B and C flutes combined
Our go-to for heavy or fragile goods, giving a higher level of transit protection. Because of the coarser outer flute, basic flexographic print tends to be used, with digital print available through our specialist print partners where finer detail is needed.
Triple wall
Triple wallapprox. 10mm+ · Three fluted layers
For heavy engineering parts, machinery and anything that needs near-crate levels of protection.
We also stock a range of liner weights and can supply kraft, white top and recycled liners. Ask us for a sample in two or three grades and test them with your real product.
Weight ranges are indicative only. Final board specification depends upon box dimensions, product weight, distribution conditions, stacking requirements and environmental conditions.
Next step
Brief, sample, supply
Tell us what you're packing and we'll spec it, sample it and supply it. No obligation and no hard sell.
Case study
Lifeplus Europe: a fully kerbside-recyclable packaging solution with PaperWave®
A recent example: we reviewed the Lifeplus Europe packing operation, specified PaperWave® paper air cushions in place of plastic void fill and installed the machinery and hoppers around their benches.
Read the case studyFrequently asked questions
- What is the lead time?
- Stocked lines usually reach local customers within one to two working days. Bespoke manufactured boxes depend on board supply and run size, and we confirm a firm lead time when we quote.
- Can you hold stock for me?
- Yes. Call-off stockholding lets you agree a volume, typically around three months' usage, hold it with us and draw it down as you need it, which protects your price and your cash flow.
- Do you offer assembly and contract packing?
- Yes. We assemble packs, kit components and prepare retail-ready presentations alongside manufacturing and delivery.
- Can I get a free sample?
- Almost always. Our process is brief, sample, supply, so you can test fit and drop performance before committing to a run.
- Do you print onto boxes?
- Yes. We offer flexographic printing directly for logos and handling marks, and can manage digital and lithographic printing through established specialist partners, remaining your single point of contact throughout.