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Packaging Cost Estimator
Instant pricing for all four box types — adjust any option and the price table updates live.
| Qty | Unit price | Total |
|---|---|---|
| 1 sample | ||
| 10 | ||
| 25 | ||
| 50 | ||
| 100 | ||
| 150 | ||
| 250 | ||
| 500 | ||
| 1,000 | ||
| 1,500 | ||
| 2,000 |
What determines custom packaging pricing?
Four variables drive the cost of every custom box. Understanding them helps you find the right balance between quality and budget.
Quantity
The single biggest lever. Unit cost at 1,000 boxes is often half what it is at 100. Ordering more spreads fixed production costs — setup, proofing, material prep — across more units.
Box size
Larger boxes require more corrugated material. For mailer boxes specifically, pricing scales with blank square footage — the amount of board needed to cut and fold your box. Right-sizing your box directly reduces cost.
Material
White board gives you a bright, printable surface. Kraft is the natural brown corrugated — often preferred for a sustainable aesthetic. SuperGloss adds a premium laminated finish. Material choice affects both cost and brand feel.
Print coverage
More ink area means more ink consumption and longer press time. Two-sided printing adds a significant premium — roughly 60% on top of the single-sided rate. Keep coverage light for simple text/logo branding to minimize cost.
Mailer, shipping, rigid, or folding — which box is right for you?
Each box type serves a different purpose. Here's how they compare across the dimensions that matter most to buyers.
| Mailer | Shipping (RSC) | Rigid | Folding | |
|---|---|---|---|---|
| Best for | Branded e-commerce, subscription boxes | Heavier goods, B2B fulfillment | Premium gifting, luxury retail | Cosmetics, candles, retail shelf |
| Minimum order | 10 units | 10 units | 500 units | 500 units |
| Custom dimensions | Any size (2″–20″ each side) | 7 standard RSC sizes | 9 catalog sizes | 10 catalog sizes |
| Full CMYK, up to both sides | Full CMYK, exterior | Not applicable | Not applicable | |
| Assembly | Ships flat, self-locking | Ships flat, tape-seal | Ships assembled | Ships flat, self-closing |
How much does custom packaging actually cost?
Pricing varies by box type, size, and configuration. The estimator above shows exact figures — here's the general picture to help set expectations.
Custom mailer boxes
For a mid-size mailer (around 10″ × 8″ × 4″) with light print on white board:
- 25 units~$3.50–4.50/unit
- 100 units~$2.20–2.80/unit
- 250 units~$1.80–2.10/unit
- 500 units~$1.50–1.80/unit
- 1,000 units~$1.30–1.55/unit
Smaller boxes cost less; larger boxes cost more. Use the estimator for your exact size.
Shipping boxes (RSC)
For a 12″ × 10″ × 8″ RSC in white board with light print:
- 25 units~$4.00–5.00/unit
- 100 units~$2.60–3.20/unit
- 250 units~$2.20–2.70/unit
- 500 units~$2.00–2.50/unit
- 1,000 units~$1.10–1.40/unit
Rigid & folding boxes
These box types have a minimum order of 500 units and pricing that varies by size:
- 500 unitsvaries by size
- 1,000 unitstypically lower/unit
- 2,000 unitsbest per-unit rate
Select a size in the estimator above to see exact pricing.
All figures are approximate. Use the estimator above for exact, live pricing on your specific configuration. Prices reflect current production costs and are subject to change.
How does shipping work for bulk custom box orders?
When Packwire ships your order, the method depends on how many boxes you're ordering. Smaller orders (typically under 150 lbs) ship via FedEx parcel — fast, door-to-door, with per-package tracking. Larger orders that would exceed parcel weight limits ship on pallets via LTL freight — less-than-truckload, where your order shares truck space with other freight.
Parcel (FedEx Ground)
- Typical for orders under ~150 lbs
- Door-to-door, residential delivery available
- Per-package tracking
- Faster transit for smaller quantities
LTL Freight
- Used for larger, heavier orders on pallets
- Lower cost per lb at high volumes
- Requires freight dock or liftgate at destination
- Transit 2–5 business days depending on region
Use the shipping estimate tool above to see which method applies to your order and what to expect. For LTL shipments, our Freight Class Calculator can help you understand your freight classification and estimated shipping cost.
Frequently asked questions
Is there a minimum order quantity?
Mailer and shipping boxes start at 10 units. Rigid and folding boxes have a 500-unit minimum. There are no setup fees or tooling costs — Packwire uses digital CAD cutting, so small runs are just as viable as large ones.
Are there any setup or tooling fees?
No. Traditional die-cutting requires expensive tooling that can cost hundreds to thousands of dollars. Packwire uses digital cutting, so there are no tooling or setup fees at any quantity.
Can I order a sample before committing to a full run?
Yes. Mailer boxes can be ordered as a single sample for a flat $35 fee. This lets you check the fit, finish, and print quality before placing a larger order.
How does print coverage affect price?
Light print (under 25% ink coverage) adds relatively little to the base price. Heavier coverage costs more due to ink consumption and press time. Two-sided print (printing the inside of the box) adds roughly 60% on top of the single-sided rate because it requires a second pass through the press.
What is the difference between White Board, Kraft Board, and SuperGloss?
White Board is a bright white corrugated surface — the standard for high-contrast, colorful printing. Kraft Board is the natural brown corrugated you see on standard shipping boxes; it gives a rustic, earthy aesthetic. SuperGloss is a high-gloss laminated finish that makes colors pop with a premium, magazine-quality look.
How long does production take?
Standard production is 10–14 business days after proof approval. Rush options may be available — contact us for details.
Can I change my box dimensions between orders?
Yes. Because there are no dies or tooling, you can adjust dimensions on every order at no extra cost. This makes it easy to iterate on your packaging design as your product evolves.
Does the price include shipping to my address?
The prices shown in the estimator are for the boxes themselves. Shipping is calculated separately at checkout based on your destination, order weight, and volume. Use the shipping estimate above to get a rough idea before placing your order.