Custom Tailored Boxes & Tailored Packaging
Buying a stock carton and hoping your product fits is where most packaging money gets wasted. The gap around the product has to be filled with something, the parcel gets bigger than it needs to be, and you pay freight on air every single shipment. A tailored box removes that problem at the source. We produce a lot of tailored packaging at ZEE Packaging and the savings usually surprise clients.
Fit Pays For Itself
A tailored box costs a little more in tooling and less in almost everything else.
- No void fill needed, which is a material cost removed entirely
- Smaller parcels often drop into a cheaper courier weight band
- Less movement inside means fewer damaged goods and fewer replacements
- Faster packing, since there is no filling step at the bench
- Neater presentation, because the product sits exactly where intended
- Lower storage footprint at your warehouse or fulfiller
Most clients who move to tailored packaging find the freight saving covers the tooling within the first run.
What We Need From You
Getting a tailored box right depends on the information at the start.
- The product itself where possible, since photos rarely settle it
- Filled weight, not just outer dimensions
- Whether anything ships alongside it, cables, manuals, accessories
- How it travels, retail shelf, courier network or pallet
- Any label or barcode position your fulfiller requires
- Stack height if it will sit on a pallet
Send us those and we can usually draw a tailored box within a couple of days.
- Tuck end carton everyday retail tailored packaging
- Auto lock bottom heavier products, quicker to assemble
- Roll end mailer ecommerce with a snug internal fit
- Rigid lid and base premium tailored box work
- Tray and sleeve presentation without full rigid cost
- Corrugated shipper with a die cut insert fragile or multi part items
Sizes Are Whatever You Need
There is no standard list here, which is rather the point.
- Dimensions cut to your exact product, to the millimetre
- Inserts and wells shaped around each component
- Depth adjusted for lids, caps and anything that protrudes
- Odd shapes accommodated with a bespoke dieline
- Multi item layouts arranged for how you actually pack
- Nested dielines so board waste stays low even on a custom shape
Board And Structure
- SBS C1S for printed retail tailored packaging
- Kraft board where a natural look suits the brand
- Corrugated E flute and B flute depending on load and transit
- Rigid greyboard 36pt or 48pt for the premium tier
- 18pt to 24pt on folding cartons, matched to filled weight
- Die cut paperboard or moulded pulp inserts
We specify from the weight rather than the footprint. That single habit prevents most of the failures we get asked to fix.
Efficiency Is The Green Story Here
- Less board per unit than an oversized stock carton
- No plastic void fill, since the fit does that job
- FSC certified stock, certificate available on request
- Soy based ink through the whole run
- Recycled board across most grades
- Fewer damaged goods, which is the biggest waste saving of all
How A Project Runs With Us
- 100 unit minimum, so a bespoke size stays accessible
- Free dieline drawn by our own designer
- Free 3D mockup and flat proof before anything prints
- Physical sample on request so you can test the fit with the real product
- Urgent turnaround at 5 to 8 business days
- Free shipping worldwide with nothing hidden
Frequently Asked Questions
Is a custom size much more than stock?
Less than most people assume. There is a small tooling cost, and the freight saving from a smaller parcel usually covers it well inside the first order.
Do you charge for the dieline?
No, we draw it free. That is a standard part of how we work rather than an extra line on the quote.
How much is a custom tailored box?
Rough estimate is $0.20 to $0.65 per unit for a bespoke folding carton, $0.80 to $2.00 for corrugated with an insert and $2.40 to $6.00 for rigid at moderate quantity. Tooling is a small one off. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
How long does a bespoke size take?
The dieline usually takes a couple of days from receiving your product details, then normal turnaround applies from artwork approval.
Can you design around several products at once?
Yes, and we would recommend planning the range together. One dieline family across sizes keeps both cost and look consistent.
Do we need to send the actual product?
It helps enormously. Photographs and measurements often miss a protruding cap or an awkward contour that changes the internal depth.
Can you keep the dieline for reorders?
We hold it on file, so a repeat run skips straight past drawing and proofing.
