Custom packaging cost typically ranges from £0.01 to over £20+ per unit. The custom packaging cost is influenced by several factors, including material type, box complexity, design, printing method, finishes, add-ons, order quantity, set-up fees, and logistics. Unit prices vary significantly depending on volume and setup requirements for corrugated boxes, folding cartons, poly mailers, pouches, rigid boxes, and labels. To estimate the per-unit cost, consider fixed charges, variable manufacturing costs, logistics, and order quantity. Custom packaging is generally more expensive than stock packaging because it often requires higher-grade materials and specialised printing, whereas stock packaging is cheaper due to standardisation and mass-production efficiencies. Packaging costs can be reduced by optimising dimensions, increasing order volumes, negotiating volume discounts, and eliminating unnecessary materials or finishes.
- What Factors Influence Custom Packaging Cost?
- Material Types
- Structural Complexity
- Designs and Artwork
- Printing Methods
- Finishes and Add-ons
- Order Quantity
- Tooling and Production Setup
- Logistics and Shipping
- How Much Does Custom Packaging Typically Cost by Packaging Type?
- How to Estimate Per-Unit Custom Packaging Cost for a Specific Product?
- Why Does Custom Packaging Cost More Than Stock Packaging?
- How to Reduce Custom Packaging Costs?
What Factors Influence Custom Packaging Cost?
Custom packaging cost is influenced by several factors mentioned below:
- Material Types
- Structural Complexity
- Designs and Artwork
- Printing Methods
- Finishes and Add-ons
- Order Quantity
- Tooling and Production Setup
- Logistics and Shipping
Material Types
Material selection determines the base cost. Per-unit differences between lightweight paperboard and rigid set-up boxes can range from roughly 3× to 10×.Materials vary in thickness (GSM or microns), structural strength, and recyclability; these attributes affect price, print-method compatibility, and converting requirements. Certified or recycled content typically adds 5%–50% to the base cost depending on availability and certification (e.g., FSC-certified materials).
Typical per-unit cost ranges for four common materials at mid-volume runs (5,000–20,000 units) are as follows:
| Material | Representative per-unit cost (5k–20k) |
|---|---|
| Kraft paperboard (uncoated or lightly coated) | £0.20 – £0.96 |
| Corrugated single-wall | £0.48 – £1.44 |
| Laminated flexible film (stand-up pouches) | £0.32 – £1.20 |
| Rigid chipboard (set-up luxury boxes) | £2.40 – £6.40 |
The above table explains the various material types such as kraft paperboard, corrugated single wall, laminated flexible film and rigid chipboard with their representative cost per unit for orders ranging from 5,000 to 20,000 units.
Structural Complexity
Structural complexity increases both fixed and variable packaging costs. Complex features, such as multi-piece inserts (foam or moulded pulp), magnetic closures, and die-cut windows, increase setup time and per-unit handling. One-time tooling for custom dies, windows, or moulds typically ranges from £120 to £2,400. Converting and assembly add about £0.04–£2.40 per unit, depending on run size and labour intensity. For example, a magnetic-closure rigid box may require £400 in tooling and £0.64 per-unit assembly cost.
Designs and Artwork
Designs and artwork directly increase production costs because they require extra pre-press work, colour separations, and additional proofing. Artwork elements that affect price include logo placement, full‑wrap illustrations, the number of spot colours, variable-data personalisation, die-line complexity, and barcodes. Additional setup for spot colours or licensed art can add £20–£240, and heavy retouching or colour-matching proofs may add £40–£480. For example, a single-colour logo printed on one panel often adds negligible per-unit cost, whereas a full-wrap CMYK illustration plus a spot varnish commonly adds £0.08–£0.48 per unit plus £120–£480 in one-time setup and proofing fees.
Printing Methods
Printing costs vary depending on quality, speed, and order quantity. Common methods include offset printing, digital printing, flexographic printing, rotogravure printing, and screen printing.
The table below compares common printing methods and their typical setup cost ranges.
| Printing Method | Typical setup cost |
|---|---|
| Digital printing | Near-zero plate cost; nominal file-prep fees £0–£150 |
| Offset printing | £150 – £1,000 per plate (per colour) |
| Flexographic printing | £50 – £500 per plate (per colour) |
| Rotogravure printing | £1,000 – £8,000 per cylinder |
| Screen printing | £25 – £200 per screen (per colour) |
The above table compares five printing methods, digital, offset, flexography, rotogravure, and screen printing, with their typical one-time setup costs in GBP.
Finishes and Add-ons
Finishes and add-ons increase both one-time tooling and per-unit costs. Options like embossing, debossing, metallic foiling, spot UV, varnish, or lamination require additional processing steps and machinery. These enhancements and add-ons are often used for premium branding.
The table below summarises common finish categories with their prices and cost drivers such as:
| Finishes | Typical one-time / Tooling | Key Cost Drivers |
|---|---|---|
| Lamination | £0 – £240 (roller/setup fees) | Film type (gloss, matte, soft‑touch), full‑surface vs partial, added weight and volumetric freight. |
| Spot coatings (UV / aqueous) | £0 – £240 (plate or anilox setup) | Number of spot areas, coating type (UV vs aqueous), cure time, effect on print run speed. |
| Foil stamping | £80 – £960 (metal die) | Foil area per face, hot vs cold foil, number of passes, foil colour/finish, slower press throughput. |
| Embossing / debossing | £120 – £1,200 (embossing die) | Depth and size of impression, board thickness, multi-stage embossing, additional press set time. |
| Windows / die-cuts | £120 – £800 (cutting die) | Window adhesive/seal, protective film, increased scrap rate, extra QC and finishing steps. |
| Inserts & trays (molded pulp, foam) | £160 – £4,000 (mould or tool depending on material) | Material (foam vs molded pulp), tool complexity, secondary assembly or pick‑and‑place labour, die-cut tolerances. |
The table above summarises common finish categories, typical tooling ranges in GBP, and the primary cost drivers for custom packaging.
Order Quantity
Order quantity plays a key role in custom packaging cost. Smaller orders, such as 100 units, result in higher per-unit costs, while larger orders, like 1,000 units, lower the per-unit price. Increasing order quantity directly reduces the overall packaging cost.
Tooling and Production Setup
Tooling and production setup are fixed charges that raise unit cost most at low quantities. Common tooling items include:
- Cutting dies: £100–£1,200
- Embossing/foiling dies: £150–£1,500
- Gravure cylinders: £1,000–£8,000
- Molds for rigid parts: £500–£5,000
- Pre-production samples: £25–£600
Machine calibration and test runs consume material and labour and add to upfront expenses. Production times vary: cutting dies typically take 3–10 business days; embossing and foiling require press alignment and test impressions; rigid parts usually take 2–6 weeks. Complex structures, such as multi-piece inserts, magnetic closures, or die-cut windows, increase both tooling costs and converting time, adding roughly £0.05–£3.00 per unit depending on labour intensity and run size.
Logistics and Shipping
Logistics and shipping add per-unit charges driven by weight, volume, packaging density and shipping mode. Freight components include weight surcharges that can exceed physical weight by 10%–200%, warehousing (£4–£24 per pallet per month) and clearance fees (£20–£160 per shipment). Sea shipments of palletised, flat-packed corrugated often yield per-unit freight < £0.08 for large runs, if lead time allows. Air transport of fully assembled rigid boxes can add about £0.40–£2.40 per unit.
How Much Does Custom Packaging Typically Cost by Packaging Type?
Custom packaging typically costs from about £0.01 per unit (labels) up to £20+ per unit (luxury rigid boxes); most mid-volume options range roughly £0.10–£6.00 per unit depending on material, printing, and order quantity.
The table below shows representative per-unit cost ranges in GBP by packaging type across three volume lists and typical one-time setup charges.
| Packaging Type | Low volume (100–1,000 units) | Mid volume (5,000–20,000 units) | High volume (50,000+ units) | Typical setup/one-time charges |
|---|---|---|---|---|
| Corrugated shipping box (single-wall) | £1.00 – £4.00 | £0.60 – £1.80 | £0.30 – £1.00 | £100 – £1,200 (cutting die, tooling) |
| Folding carton (coated board) | £0.80 – £3.50 | £0.25 – £1.20 | £0.12 – £0.50 | £150 – £1,500 (plates, die) |
| Poly mailer (printed) | £0.60 – £2.00 | £0.20 – £0.80 | £0.08 – £0.30 | £50 – £600 (print plate or digital setup) |
| Custom pouch (stand-up, laminated) | £0.90 – £3.50 | £0.40 – £1.50 | £0.20 – £0.80 | £300 – £2,500 (gravure cylinder or tooling) |
| Rigid set-up box (luxury) | £6.00 – £20.00+ | £3.00 – £8.00 | £2.00 – £5.00 | £500 – £5,000 (mould, tooling) |
| Labels & stickers (roll or cut) | £0.03 – £0.50 | £0.01 – £0.10 | £0.005 – £0.03 | £25 – £300 (plate / label die) |
The table above explains the typical per-unit price bands and one-time setup charges for six common packaging types (corrugated shipping boxes, folding cartons, poly mailers, custom pouches, rigid set-up boxes, labels).
How to Estimate Per-Unit Custom Packaging Cost for a Specific Product?
To estimate the per-unit custom packaging cost for a specific product, you must include all direct and indirect expenses such as:
- Fixed costs including tooling, plates, moulds, design and samples. Add all one-time charges as a single sum (example values below).
- Variable costs including material, printing, converting, inserts and assembly expressed per unit (use supplier unit rates).
- Logistics & duties including freight, palletising, handling, customs and warehousing; express as total and per unit.
- Quantity includingdivide total fixed costs by the planned run size; larger runs lower the fixed per-unit share.
- Total per-unit cost: Fixed per-unit + variable per-unit + logistics per-unit.
Example (Folding Carton):
- Fixed costs: £1,270 (design £400, sample £120, plates/die £600)
- Variable per-unit: £0.80
- Logistics total: £150
- Quantity: 1,000 units
Calculation:
- Fixed per-unit = £1,270 ÷ 1,000 = £1.27
- Logistics per-unit = £150 ÷ 1,000 = £0.15
- Total per-unit = £1.27 + £0.80 + £0.15 = £2.22
Why Does Custom Packaging Cost More Than Stock Packaging?
Custom packaging costs more than stock packaging because fixed setup and tooling (£100–£5,000), higher-grade materials (often 3×–10× the price), custom printing and finishes (plates, foils, embossing), and additional assembly increase both upfront and per-unit costs, especially at low quantities. On the other hand, stock packaging is mass-produced with standard designs and sizes, making it more cost-effective.
How to Reduce Custom Packaging Costs?
Reduce costs by optimising carton size to the product, increasing order quantity, and removing unneeded inserts (foam, moulded pulp) or high-cost finishes. Optimise dimensions to cut material and volumetric freight; pack flat for sea shipments to lower transport per-unit. Choose digital printing for runs under 5,000 units, use standard sizes and shared components (dies, inserts), and negotiate pallet or volume discounts with suppliers.
