Custom Litho Laminated Boxes & Litho Laminated Packaging
Corrugated is strong and prints poorly. Paperboard prints beautifully and is not strong enough to ship. Litho lamination solves that by printing a paper sheet properly and then bonding it onto corrugated board. You get retail print quality with shipping strength. We produce a lot of litho laminated packaging at ZEE Packaging and this is the format that bridges the two worlds.
Two Materials Bonded Together
A litho laminated box combines a printed sheet with corrugated.
- The top sheet prints on a litho press at full quality
- That sheet is then glued onto corrugated board
- You get photographic print on a shipping strength material
- Flexo printing directly on corrugated cannot match it
- The flute no longer shows through the printed surface
- Color reproduction matches a retail folding carton closely
Most brands ordering a litho laminated box need retail print on something that also survives a courier.
It costs more than flexo, so it has to earn that.
- Retail display where print quality drives the sale
- Products photographed by customers on arrival
- Ecommerce packaging doubling as brand experience
- Shelf ready packaging in supermarkets
- Premium electronics and appliance cartons
- Not worth it for a plain outer nobody sees
- Regular slotted carton the standard litho laminated box
- Roll end tuck front mailer ecommerce litho laminated packaging
- Die cut shipper display tearing open into a retail unit
- Full overlap container doubled faces with retail print
- Two piece tray and lid heavier premium products
- Counter display unit full color retail display
Sizes We Print Regular
Every litho laminated box is built to your product, though these run often:
- 8" x 6" x 4" for a standard order
- 10" x 8" x 4" for an ecommerce mailer
- 12" x 9" x 6" for a mid size product
- 16" x 12" x 10" for larger goods
- 14" x 10" x 5" for a display format
- 20" x 16" x 12" for bulk items
Board And Print
- E flute for the smoothest printed surface
- B flute where more strength is required
- Double wall for heavy products with retail print
- SBS C1S top sheet for the best reproduction
- Matte, gloss and soft touch lamination over the print
- Spot UV and foil applied to the top sheet
E flute gives the flattest result. On B flute the fluting can show faintly through the sheet, which we would mention before you specify it.
Materials Worth Weighing
- Recycled corrugated beneath the printed sheet
- FSC certified board, certificate available on request
- Soy based ink through the whole run
- Aqueous coating rather than plastic film where possible
- The bonded sheet does complicate recycling slightly
- Right sizing so no board is wasted per unit
Plain flexo on corrugated recycles more cleanly. Where print quality is not critical, we would say so rather than upsell you.
What Happens On Your Order
- 100 unit minimum, so a small brand can order properly
- Free 3D mockup and flat proof before anything prints
- Free dieline drawn by our own designer
- Physical sample on request to check print and strength together
- Urgent turnaround at 5 to 8 business days
- Free shipping worldwide with nothing hidden
Frequently Asked Questions
How much do litho-laminated boxes cost?
Rough estimate is $0.90 to $2.20 per unit for a mailer, $1.60 to $3.60 for a larger carton and $2.40 to $5.50 for display formats at moderate quantity. Size moves it. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
Litho lamination or flexo?
Litho where print quality matters to the customer. Flexo where the box is a plain shipper nobody photographs.
Will the flute show through?
Barely on E flute, faintly on B flute. If a perfectly flat surface matters, E flute is the safer choice.
Is it as strong as plain corrugated?
Effectively yes, since the corrugated underneath is unchanged. The sheet adds print rather than removing strength.
Can we print inside too?
Yes, though it adds a second lamination. Many brands print the outside litho and the inside flexo to control cost.
Does it take foil?
It does, applied to the top sheet before lamination. Spot UV works the same way.
Is it recyclable?
Reasonably, though the bonded sheet complicates it slightly compared with plain flexo printed corrugated.
