Creating new direct to consumer packaging can be unexpectedly challenging as well as expensive.
In many cases, a cutting die for the shipper box is necessary to be able to produce the exact size required. If a custom designed insert is desired, a separate, custom cutting die will also need to be purchased. Beyond the structural design, the vast majority of the boxes we produce are custom printed using a low-cost flexographic print process, but you can add the one-time cost for print plates to your pre-production expenses. The price for print plates is typically determined by the number of ink colors necessary per side (inside and/or outside).
Needless to say, the numbers add up very quickly, especially if you have a very colorful graphic design or a sophisticated structural design. If your plan includes multiple package sizes, these pre-press expenses can make it almost cost prohibitive.
Salazar Packaging Can Help Minimize New DTC Box Costs
Even from our beginning in 2007, we recognized one of the best ways we could help make great packaging affordable is to minimize these preliminary expenses. After millions of boxes produced for well over a thousand customers, we have learned how to save our customers money. These include:
- Minimize box sizing because it saves on cutting dies and print plates. Less steel rule and less rubber used on print plates.
- Keep insert designs as simple as possible. Cutting dies are priced based on the number of linear inches of steel rule that is required. A simple, not overly complicated design also saves forming and packing time.
- Select a designer who understands the economics of a new, packaging design. This is very important, especially if your company is in start-up mode.
- Determine if your application is better satisfied with our semi-custom approach that may save you thousands of dollars.
How do semi-custom and fully custom boxes differ?
On a fully custom box, we can produce the exact size you want to one-sixteenth of an inch. For example, if you decide you want a box that is 12-1/8” long X 6-15/16” wide X 3-3/4” high, we can produce a box with those exact measurements. If, however, a box with dimensions of 12-1/2” X 7” X 4” will work for you, one of our stock cutting dies might be available saving you approximately $1,400. This is an estimate because new custom size steel rule cutting dies have increased in price between 20% and 30% in the last two years. I’ve not heard a good excuse why, but that is the market right now.
The advantage of pre-made stock cutting dies. 
We currently have over 140 cutting dies in stock and available for you to use, at no cost. There is no guarantee we will have the exact size you want, but the majority of our stock dies were made for the most often requested e-commerce sizes. Whether your product is lingerie, greeting cards, or pet food, we probably have something very close to what you need.
Why is this important? This available stock cutting die program was created for new, start-up companies or existing companies launching a new product. It has also proven valuable for customers who have a seasonal gift program, or a promotional short run. Keep in mind that saving money is great, but utilizing an existing cutting die can also save you valuable time.
From the very beginning we have always felt we did not want pre-production costs preventing a customer from getting what they really want and need. For that reason, cutting dies and print plates have never been marked up to make them profitable line items for us.
Our experienced (10 years average) branded packaging advisors are standing by, waiting to discuss your specific application and needs. Call us at 630-551-1700 or contact us via this web site and link.
Related posts:
https://www.salazarpackaging.com/custom-industrial-boxes/
https://www.salazarpackaging.com/refresh-or-rebrand-your-e-commerce-packaging/
https://www.salazarpackaging.com/category/packaging-solutions/
http://www.salazarpackaging.com/how-shifts-in-consumer-purchasing-impacts-e-commerce/