Create Your Own Rigid Packaging Boxes

Custom Rigid Boxes & Luxury Rigid Packaging

There is a moment when somebody lift the lid off a rigid box and it come away slow, with that little suction sound. You cant fake that with a folding carton. That weight and resistance is the whole reason luxury brand keep coming back to rigid packaging even though it cost more.

We build a lot of set up box work at ZEE Packaging, and honestly it is the category where the difference between good and cheap show up fastest.

What Makes A Rigid Box Different

A rigid box is built from greyboard, chipboard or binder board, cut and formed into a permanent shape, then wrapped in printed paper or specialty material. It arrive to you already assembled. That is why it is called a set up box, it come set up.

Folding carton get printed then folded. A rigid box get constructed then covered. Two completely different process, and it is why rigid packaging cost more to ship.

• Holds it shape permanently, no folding
• Board is 4 to 10 times thicker than a carton
• Wrap paper carry the print, not the board
• Feels heavy in hand, which is most of the perceived value
• Reusable, people keep a good luxury box

Styles Of Set Up Box We Make

1. Lid and base (two piece) the classic set up box, lid lift straight off
2. Shoulder neck box inner neck wall, lid sit flush, very premium rigid packaging
3. Magnetic closure box book style flap with hidden magnet, our most requested luxury box
4. Drawer or slide box inner tray slide out of a sleeve
5. Hinged lid box attached lid, no separate piece to lose
6. Book style rigid box opens like a hardcover
7. Collapsible rigid box ships flat then locks up, saves freight on rigid packaging
8. Round or shaped set up box cylinder, hexagon, custom die form

Board, Wrap And Sizes

The board is what you feel, the wrap is what you see.

Board options:

• 1mm (about 28pt) light rigid box, small item
• 1.5mm (36pt) our standard for most set up box work
• 2mm (48pt) heavier luxury box, this is the common premium spec
• 2.5mm and 3mm for oversized rigid packaging

Wrap materials:

• Art paper 128 to 157 GSM, most common, takes full color
• Uncoated fine paper for a matte natural feel
• Specialty texture, linen, leatherette, felt
• Kraft wrap for organic luxury box
• Fabric and velvet for jewelry rigid packaging

Sizes we run often:

• 4" x 4" x 2" for candle and jewelry rigid box
• 6" x 4" x 2" for cosmetic set
• 8" x 6" x 3" for gift and hamper set up box
• 10" x 8" x 3" for apparel and shirt rigid packaging
• 12" x 9" x 4" for electronics and multi piece kit
• 14" x 10" x 4" for large presentation rigid box

Every dimension is custom anyway, so send us your product measurement and we build the structure around it.

Print And Surface Work

Because the print goes on the wrap sheet, you get all the finishing option a flat sheet allow.

• Offset print on the wrap, CMYK plus Pantone
• Matte, gloss or soft touch lamination
• Hot foil stamping, gold, silver, rose gold, holographic
• Emboss and deboss, works beautifully on a rigid box lid
• Spot UV over matte for contrast
• Screen print direct on uncoated wrap
• Debossed logo with no ink at all, very quiet and very expensive looking

Soft touch plus a single blind deboss is our most recommended combination for a luxury box that dont look try hard.

Inside The Set Up Box

Interior is half the job with rigid packaging.

• EVA foam insert, cut to product shape
• Molded pulp insert, more sustainable
• Paperboard platform and cradle
• Velvet or satin lined tray for jewelry rigid box
• Ribbon pull tab so product lift out easy
• Printed inner wrap or lining paper
• Magnet strength, we can go soft close or firm snap

Where Rigid Boxes Get Used

• Perfume and fragrance rigid packaging
• Watch and jewelry set up box
• Consumer electronics and headphone
• Spirits, wine and premium beverage
• Cosmetic and skincare gift set
• Corporate gift and onboarding kit
• Apparel, footwear and accessory luxury box
• Confectionery and chocolate rigid box

Sustainability Side

• Recycled greyboard core in every rigid box we make
• FSC certified wrap paper, certificate on request
• Soy based ink
• Molded pulp insert instead of EVA foam
• Collapsible rigid packaging to cut freight volume
• Uncoated wrap that recycle easier than laminated

How We Handle Your Order

• 100 unit minimum on rigid box, though 500 plus get better pricing
• Free 3D mockup and flat proof
• Physical sample on request, we recommend it for set up box
• Free structural design and dieline
• Turnaround from 15 business day, rigid takes longer than carton
• Free shipping worldwide

Frequently Asked Questions

Can you tell me the cost of a rigid box?
Rough estimate is $1.80 to $45.50 per unit at moderate quantity. Magnetic closure, foam insert and foil push it toward the upper end. Shipping is included in our price. This is estimate only, so get a exact quote from our team.

What is the difference between a rigid box and a setup box?
They are the same product wearing two names. Setup box is the older printing trade term because the box comes to you already set up. Rigid box is what most retail and luxury rigid packaging buyers say today.

Why is rigid packaging more expensive than folding carton?
More board, more labor, and it ship assembled so freight cost more. A set up box is partly hand made, that is the honest reason.

Can a rigid box ship flat to save money?
A collapsible one can. Standard set up box cant, it come pre formed. If freight is your concern, ask us about collapsible.

How strong are the magnet?
We offer soft close and firm snap. For a heavy lid we use stronger magnet, and we always test it on the sample before production.

Whats the minimum board thickness you recommend?
1.5mm for most thing. Go 2mm if the box is over 8 inch or if the product has any weight to it.

Can you match my brand color on textured wrap?
On smooth art paper yes, very accurate. On linen or leatherette texture the color read slightly different, so we always send a sample first.

Do you make the foam insert too?
We do. EVA foam, molded pulp or paperboard, whichever suit your budget and how much protection the product need.

How long does rigid production take?
Longer than carton, plan 15 to 30 business day depending on finishing. Foil, magnet and custom insert all add time.