Shoppers often give a product only a second or two before moving on. Well planned custom display packaging helps your item win that moment while protecting stock on the journey from factory to shelf. This guide covers the main formats, materials and cost factors so you can brief a supplier clearly.

How a Display Unit Works

A display unit is a carton built to hold several products and show them without unpacking each one. It usually opens with a tear strip, a hinged lid or a cut away front panel, so staff can place it straight onto a counter or shelf.

The aim is to save time and keep stock tidy. A good unit also leaves space for a logo, price panel or promotional message at eye level.

Formats and Where They Fit

The best format depends on where the product will sit and how quickly it sells. Four options cover most requests:

• Counter boxes: small units for impulse items such as sweets, cosmetics and accessories.
• Shelf ready trays: corrugated trays with a perforated lid that tears away for fast restocking.
• Floor standing displays: tiered units for seasonal promotions and new launches.
• Pallet displays: large corrugated shells that hold a full pallet of stock for supermarkets.

Smaller retailers often start with counter units, as they cost less and need no floor space.

Materials and Board Strength

Corrugated board is the usual choice for anything that must stand upright and carry weight. Single wall E or B flute suits lighter counter units, while double wall board is better for floor displays holding heavier goods.

Folding carton board of around 300 to 400 GSM works well for small, light units with sharp printing. For anything touching food, ask your supplier for board suitable for direct contact and confirm it meets UK food contact rules.

At Boxo Packaging, we usually ask for product weight, shelf height and the number of units per display before suggesting a board grade. These details decide wall thickness far more than appearance does.

Printing and Finishing Choices

Digital printing suits short runs and frequent design changes. Offset printing gives richer colour and a lower unit price on larger orders, while flexographic printing is common directly on corrugated board.

Matt lamination, spot UV and foil add a premium look, though each raises the cost. A bold one or two colour design on kraft board can still stand out and stay affordable.

Cost Factors and Sustainability

Order quantity has the biggest effect on price, since setup and tooling are spread across more units. Board grade, size, print colours and finishing then add to the total, and a new cutting die is a one off charge.

Look for FSC certified board, water based inks and single material designs that recycle more easily. Avoid claiming a box is “fully green”, as every material has some footprint. Plastic windows and heavy lamination can complicate recycling.

Ordering Tips Before You Commit

Request a physical sample and fill it with real stock. Check that it stays upright when loaded, that the front panel does not sag and that staff can assemble it quickly.

Allow extra lead time, since production and freight can take several weeks. A reliable supplier will question your specification rather than simply accept it. That is how we work at Boxo Packaging, because fixing a problem early costs far less than a reprint, especially with custom display packaging.

Retail Boxes: A Practical Guide for Shelf and Online Sellers

A customer usually handles the box before they ever try the product inside. Well planned retail boxes protect the contents, carry your branding and help an item stand out beside its competitors. This guide covers the main styles, materials and cost factors so you can brief a supplier clearly.

What Sets a Retail Box Apart

A retail box is a printed carton that holds a product at the point of sale and goes home with the buyer. Shipping cartons are different, as they are plain and built mainly to survive transit.

Most are made from folding carton board or thin corrugated board. They arrive flat and are assembled by hand or on a packing line.

Styles Worth Considering

The right style depends on product size, weight and where it will be displayed. Four options cover most requests:

• Tuck end boxes: a simple, low cost shape for supplements, soaps and small accessories.
• Sleeve boxes: a tray with a printed outer cover, popular for candles and gifts.
• Hanging boxes: cartons with a punched tab for pegboard racks in pharmacies and convenience stores.
• Window boxes: a die cut opening that lets shoppers see the item before buying.

If you sell in shops and online, pick a style that survives courier handling as well as looking good on a shelf.

Materials and Board Weights

Folding carton board of 300 to 400 GSM is the usual choice for lightweight items. White SBS board gives a smooth surface for sharp colour, while kraft board suits natural or handmade brands.

Heavier or fragile goods may need E flute corrugated board for added rigidity. For anything touching food, ask your supplier for board suitable for direct contact and confirm it meets UK food contact rules.

At Boxo Packaging, we usually ask for product weight, dimensions and sales channel before suggesting a board grade, since a shelf item and a posted item need different strength.

Printing and Finishing Options

Digital printing suits short runs and frequent design changes. Offset printing gives richer colour and a lower unit price on larger orders.

Matt lamination, spot UV, foil and embossing add a premium feel, though each raises the cost. A simple one or two colour design can look smart and stay affordable.

Cost Factors and Sustainability

Order quantity has the biggest effect on price, since setup and tooling are spread across more units. Board grade, size, print colours and finishing then add to the total, and a new cutting die is a one off charge.

Look for FSC certified board, water based inks and single material designs that recycle more easily. Avoid claiming a box is “fully green”, as every material has some footprint. Plastic windows and heavy lamination can complicate recycling.

Ordering Tips Before You Commit

Request a physical sample and fill it with real stock. Check the dieline proof, test the closure and drop a packed box from a realistic height.

Allow extra lead time, since production and freight can take several weeks. A reliable supplier will question your specification rather than simply accept it. That is how we work at Boxo Packaging, because fixing a problem early costs far less than a reprint, especially with retail boxes.