Custom Automotive Boxes & Automotive Packaging
Car parts are heavy, greasy, oddly shaped, and half of them have a sharp edge somewhere. That combination breaks more cartons than most people realize. We print a lot of automotive packaging at ZEE Packaging and the conversation almost always starts with weight before it gets to branding.
Weight Decides Everything Here
The first question we ask is what does the part weigh and does it have oil on it. A brake pad set and a set of wiper blades need completely different automotive box construction even if the outer dimensions look similar.
Rough guide we use:
- Under 1 lb, cardstock automotive box works fine
- 1 to 5 lb, single wall E or B flute corrugated
- 5 to 20 lb, B or C flute, sometimes double wall
- Over 20 lb, double wall automotive box with reinforced flap
A 24pt carton holds a set of spark plugs no problem. Put a caliper in it and the bottom goes through on the first drop.
Sizes We Print Most Often
Every automotive box we make is custom, but these come up again and again:
- 8" x 4" x 3" for spark plugs, sensors and small electrical parts
- 10" x 6" x 3" for brake pad sets, our most requested automotive box
- 12" x 9" x 3" for filters, belts and hoses
- 14" x 10" x 4" for alternators, starters and pumps
- 20" x 6" x 6" for shock absorbers and struts
- 24" x 18" x 4" for body panels and trim pieces
Send us the part measurements with any protruding brackets included, or ship a sample here and we will build the dieline around it.
Styles That Actually Hold Up
- Regular slotted carton the standard shipping automotive box, cheap and strong
- Die cut mailer crash lock bottom, no tape, good for ecommerce automotive packaging
- Tuck end carton retail automotive box for small parts on a peg or shelf
- Full overlap carton double thickness on top and bottom, for heavy items
- Two piece tray and lid nice for premium performance parts
- Corrugated with hang tab retail automotive box built for peg display
Inside Protection Is Not Optional
Most damage claims we see come from movement inside the box, not from the box failing.
- Die cut corrugated insert to lock the part in place
- Fluted pad and layer pad between multiple items
- Corner block for anything with a sharp edge
- Grease resistant liner for oily parts
- VCI paper for bare metal that rusts in humidity
An automotive box with a proper insert survives far more handling than a bigger box full of loose fill.
Print And Finish For Aftermarket Shelf
Retail automotive packaging lives on a crowded shelf next to twenty competitors, so the front panel needs to work hard.
- Full CMYK and Pantone print, offset or digital
- Kraft corrugated with one or two color flexo for economy lines
- White top corrugated when you want photo quality on a shipping automotive box
- Matte or gloss lamination on retail automotive boxes
- Spot UV and foil for performance and premium ranges
Do not forget the part number. We tell clients to put it on at least three panels, big and clear, because warehouses pick from whatever face is showing.
Compliance And Data On Pack
- Part number and OEM cross reference
- Barcode and QR code with proper quiet zone
- Vehicle fitment or application list
- Country of origin
- Handling marks and weight declarations on heavy automotive boxes
- Batch or lot space for coding
Our prepress team checks all of it against the dieline before press so nothing gets trimmed.
Greener Options
- Recycled corrugated automotive boxes, most of our stock already is
- FSC certified board, certificate on request
- Water and soy based inks
- Paperboard inserts instead of foam
- Right sized automotive packaging cuts your freight cost too
How We Work
- 100 unit minimum on any automotive box design
- Free 3D mockup and flat proof
- Free dieline support from our own designer
- 5 to 8 business day urgent turnaround
- Free shipping worldwide
Frequently Asked Questions
Will corrugated handle oil and grease?
Plain board will absorb it. We use a grease resistant liner or a poly bag inside the automotive box for anything wet.
What does an automotive packaging boxes cost?
Its approximately $0.45 to $2.20 per unit for folding cartons, $1.10 to $5.00 for corrugated mailers and shippers, and $2.50 to $8.00 for rigid or two piece boxes at moderate quantities. Shipping included in our price. This is estimate only so ask our team for a exact figure.
Can you do the retail box and the shipper together?
Yes, plenty of clients order both in one job so the print and color match across the set.
Do you supply inserts too?
We do. Die cut corrugated inserts are made in the same run as the box so the fit is exact.
What about heavy parts like a starter motor?
Double wall corrugated with full overlap flaps. We also add corner protection if the casting has sharp edges.
Can we get hang tabs for peg display?
Yes, either a die cut euro hole or an applied hang tab depending on the weight it needs to carry.
Do you print part number variable data?
We print fixed art. For variable part numbers most clients run a label applied in their own warehouse.
Small run for a new SKU?
That is what our 100 unit minimum is for. Test low moq, see how it performs in the field, then scale.