We offer a variety of custom packaging products and solutions to meet all your packaging needs in one place. You’ll work directly with a dedicated project specialist to customize your package according to your specifications, including branding, features, and design.
Corrugated Boxes
Folding Cartons
POP Displays
Pouches
Foam
Additional Packaging
Our stock packaging products, from corrugated boxes to stretch film, offer a wide selection, including essentials like tape, edge protectors, labels, and more, with quick turnaround times to meet your packaging needs efficiently.
Our stock packaging products, from corrugated boxes to stretch film, offer a wide selection, including essentials like tape, edge protectors, labels, and more, with quick turnaround times to meet your packaging needs efficiently.
We build durable and efficient packaging for simple to the most complex products.
Sterilization, clean room and medical compliant packaging products and solutions.
We serve a wide variety of businesses including: pet, toy, cosmetic, electronic and more.
At Brown Packaging, we help our clients create unique packages that reflect their brand and produce results. As a result, we look to add as much value to your packaging experience and product as possible with our services.
Optimize Your Packaging with Structural Design Services
Our structural design services optimize your packaging by enhancing durability and reducing material use, which leads to cost savings and increased sustainability. By focusing on efficient design, we help improve product protection, reduce shipping costs, and minimize environmental impact. These tailored solutions also boost your brand’s shelf presence, making your packaging both functional and attractive.
Optimize Your Packaging with Structural Design Services
Our structural design services optimize your packaging by enhancing durability and reducing material use, which leads to cost savings and increased sustainability. By focusing on efficient design, we help improve product protection, reduce shipping costs, and minimize environmental impact. These tailored solutions also boost your brand’s shelf presence, making your packaging both functional and attractive.
Our sustainable packaging products are designed to minimize environmental impact while maintaining top-notch quality and durability. Choose from a variety of eco-friendly materials, inks, prints and other customizable options to meet your sustainability goals.
Full-Service Packaging
Get all your packaging needs from one supplier, guiding you from concept to completion.
Flexible Solutions
We offer packaging options to suit the needs of any brand and budget.
Expert Assistance
Work one on one with a dedicated project manager from concept to completion.
Compliant Solutions
Our packaging solutions meet both retailer requirements and government regulations.
Full-Service Packaging
Get all your packaging needs from one supplier, guiding you from concept to completion.
Flexible Solutions
We offer packaging options to suit the needs of any brand and budget.
Expert Assistance
Work one on one with a dedicated project manager from concept to completion.
Compliant Solutions
Our packaging solutions meet both retailer requirements and government regulations.
If you need any assistance with your packaging or have a question, then contact us directly at request@brownpackaging.com or (714)300-0650. Learn more about packaging by reading our blog posts on new and trending topics.
Point-of-purchase (POP) displays play a dual role in retail environments: they must capture attention with graphics while supporting products with reliable structure. If one side is overemphasized, the other suffers—eye-catching graphics on a weak structure can lead to product collapse, while overbuilt displays with poor graphics fail to drive sales. Successful POP design requires careful coordination between visual branding and engineering strength. The Role of Graphics in POP Displays Graphics carry the brand message and attract consumer attention in crowded retail aisles. Effective use of color, typography, and imagery transforms a standard corrugated display into a compelling marketing tool. Reinforces brand identity. Highlights product features or promotions. Differentiates products from competitors on the same shelf. However, graphics must be placed with consideration of die lines, folds, and assembly points. A design that looks strong in concept may lose effectiveness if critical elements are cut or hidden during production. Structural Integrity and Functionality The best POP display design balances aesthetics with durability. Structural engineering ensures the display holds weight, withstands handling, and complies with retailer requirements. Load-bearing capacity: Displays must hold multiple units without sagging. Assembly efficiency: Designs should be easy to set up in stores. Retail compliance: Dimensions must fit within chain-specific guidelines. Ignoring structure risks costly failures on the retail floor, from leaning displays to complete collapse. Achieving Balance Between Graphics and Structure Collaborative design: Graphic and structural designers should work together from concept through prototype. Testing in real-world conditions: Simulate load, handling, and lighting before production. Material selection: Choose board grades and coatings that allow high-quality print while maintaining rigidity. Print-to-structure alignment: Ensure graphics align with folds, cutouts, and SKU placement. Industry Examples Club stores: High-traffic environments demand bold graphics paired with strong pallet displays. Seasonal promotions: Graphics drive excitement, but structural resilience ensures displays last through extended campaigns. Cross-merchandising displays: Must hold different SKUs securely without compromising print impact. POP Display Solutions with Brown Packaging At Brown Packaging, we engineer POP displays that balance structural integrity with brand-forward graphics. From retail-ready pallet displays to seasonal floor stands, our team ensures your design attracts attention without sacrificing performance. Contact us to start planning your next POP display. References Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.Shop! Association. (2021). Best Practices for In-Store Marketing and POP Displays. Retrieved from https://www.shopassociation.orgASTM International. (2022). ASTM D642: Standard Test Method for Determining Compressive Resistance of Shipping Containers. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. POP Display Facebook Twitter LinkedIn Pinterest Relevant Posts
Point-of-purchase (POP) displays must catch a shopper’s eye while also moving efficiently through the supply chain. Striking the right balance between visual impact and logistics ensures displays drive sales without creating costly inefficiencies. A design that leans too far toward graphics may ship poorly, while one built only for logistics risks blending into the background. The Role of Visual Impact Graphics and structure are central to a display’s retail performance. Visual impact drives traffic and communicates the brand message at a glance. Bold colors and large product imagery attract attention. Clean layouts improve readability in busy aisles. Seasonal themes and promotions build urgency. Without strong branding, even the most efficient display may fail to engage shoppers. Logistics Demands in POP Displays Retailers expect displays that not only sell but also ship and set up efficiently. Logistics considerations include: Cube efficiency: Displays should maximize pallet and trailer space. Durability: Strength to withstand transit and handling. Ease of assembly: Retail staff need quick setup without extra labor. Compliance: Dimensions must meet retailer guidelines for footprint and safety. Strategies to Balance Both Sides Collaborative design: Structural and graphics teams work together from the start. Prototype testing: Confirm visual alignment and shipping durability before production. Material selection: Choose corrugated grades that allow high-quality print and strength. Right-size graphics: Design branding that adapts to fold lines and pallet constraints. Examples of Balanced POP Designs Club store pallet displays: Large branding surfaces combined with pallet-ready engineering. Seasonal promotions: Bold graphics with lightweight, compact shipping formats. Cross-merchandising units: Multi-SKU designs that showcase brands while stacking efficiently. POP Display Solutions with Brown Packaging Brown Packaging creates POP displays that deliver both retail impact and supply chain efficiency. Our designs maximize brand presence while meeting freight, compliance, and setup demands. Contact us to explore display options that balance impact with logistics. References Shop! Association. (2021). Best Practices for In-Store Marketing and POP Displays. Retrieved from https://www.shopassociation.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.ASTM International. (2022). ASTM D685: Standard Practice for Conditioning Paper and Paper Products for Testing. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. POP Display Facebook Twitter LinkedIn Pinterest Relevant Posts
High-speed automated packaging lines can run hundreds of cartons per minute, but only if the carton’s design and material are optimized for smooth feeding, folding, and sealing. Small structural or material missteps can lead to jams, misfeeds, and costly downtime. This guide covers the critical design, tolerance, and substrate considerations for folding cartons intended for high-speed automation. Dimensional Accuracy Automated lines demand tight dimensional control in die cutting. Die Cut Precision: Carton blanks must be within ±0.015 inches for consistent feeding and folding (Soroka, 2014). Blank Squareness: Even minor skew can cause issues with glue flap alignment or panel folding. Caliper Consistency: Variations in board thickness can change fold behavior and sealing pressure. Scoring and Creasing Profiles High-speed folding relies on scores that create predictable, repeatable folds. Score Depth and Bead Width: Too shallow causes spring-back; too deep risks cracking. Bead/Channel Ratio: Must match board caliper and fiber composition for clean folding at speed. Grain Direction: Scores parallel to grain can crack if bead pressure isn’t optimized. Glue Flap Design Flap dimensions and positioning are critical for automated glue application. Flap Width: Minimum 10–12 mm recommended for cold glue; narrower flaps risk bond failure. Glue-Free Zones: Essential near scores to prevent squeeze-out during folding. Coating Considerations: Gloss varnish or film lamination in glue areas requires corona treatment or glue type adjustment for proper adhesion. Material Selection Not all boards perform equally on automated lines. SBS: Smooth feeding, excellent fold consistency, best for high-graphic retail cartons. CUK: Added stiffness and moisture resistance for cold chain or beverage applications. FBB/Recycled: Economical, but may need adjusted scoring to reduce cracking at speed. Folding Sequence Compatibility Structural design must align with the machine’s folding sequence. Tuck End Cartons: Ensure flap lengths are balanced to avoid collision in the folding belts. Auto-Bottom Designs: Verify glue flap and lock panels don’t bind during machine erection. Full Seal End: Flap lengths and bevel angles must accommodate sealing jaws without interference. Surface Coatings and Friction Carton surfaces influence how blanks travel through feeders and conveyors. High Gloss Coatings: Can cause feeding slippage; mitigated with anti-slip varnish zones. Poly Coatings: Increase stiffness but may alter fold memory—test for score cracking before production. Matte Varnish: Generally more forgiving in high-speed feeders. Machine Trials and Prototyping Before committing to a production run: Run on the Target Machine: Testing on actual equipment verifies compatibility. Check Across Speed Range: A carton may run well at 100 cpm but fail at 300 cpm. Inspect Post-Run Samples: Look for misaligned folds, glue squeeze-out, or score fractures. References Soroka, W. (2014). Fundamentals of packaging technology (5th ed.). Institute of Packaging Professionals. ISBN: 978-1-930268-37-2 Twede, D., & Goddard, R. (2021). Cartons, crates and corrugated board: Handbook of paper and wood packaging technology (2nd ed.). DEStech Publications. ISBN: 978-1-60595-120-5 (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Folding Cartons Facebook Twitter LinkedIn Pinterest Relevant Posts
When choosing corrugated packaging, box style directly impacts cost, strength, speed of packing, and customer experience. Two of the most common options are the Regular Slotted Container (RSC) and the Roll-End Tuck-Top (RETT) mailer. While both protect products well, their design differences make each suited for very different needs. Regular Slotted Container (RSC) Design & Features Flaps of equal length meet in the center. Requires tape, glue, or staples for closure. Minimal board waste, highly efficient to manufacture. Advantages Strong and Stackable: Excellent compression strength for palletized loads. Cost-Efficient: Standardized design lowers production cost. Versatile: Common in nearly every industry. Limitations Slower Assembly: Tape or glue required for every box. Basic Presentation: Not designed for branded unboxing experiences. Roll-End Tuck-Top (RETT) Mailer Design & Features Single-piece die-cut design. Built-in dust flaps protect contents from debris. Cherry locks (small locking tabs) keep the lid secure without tape. Advantages Fast Assembly: Self-locking design saves time and eliminates tape. Premium Look: Ideal for branded unboxing and e-commerce. Better Closure: Dust flaps improve integrity; cherry locks prevent accidental opening. Limitations Higher Cost: Requires custom tooling and more board. Lower Stacking Strength: Not as durable for bulk palletized shipping. Less Flexible for Large Sizes: Best suited to small-to-medium e-commerce parcels. RSC vs. RETT: Side-by-Side Comparison Feature RSC Box RETT Mailer Closure Method Tape, glue, or staples Dust flaps + cherry locks (self-locking) Assembly Speed Slower Faster Stacking Strength High (pallet loads) Moderate Cost Lower Higher Branding & Unboxing Basic Premium Best For Bulk shipping, warehousing, palletization E-commerce, subscription boxes, retail-ready packaging Regular Slotted Container (RSC) Roll End Tuck Top (RETT) with cherry lock and dust flaps Buyer Takeaways Choose an RSC if you need maximum stacking strength and shipping efficiency. Perfect for palletized loads, warehouses, and industrial distribution. Choose a RETT mailer if your focus is branding, presentation, and fast assembly. Ideal for e-commerce, D2C shipments, and subscription boxes. Dust flaps and cherry locks make RETT mailers especially well-suited to online retail, where presentation and secure delivery both matter. References Fibre Box Association. (2023). Corrugated Box Styles and Design Guide. https://www.fibrebox.org Association of Independent Corrugated Converters (AICC). (2024). Corrugated Packaging Fundamentals. https://www.aiccbox.org (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Corrugated Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts
The holiday season pushes packaging supply chains to their limits. With surging e-commerce demand, constrained carrier capacity, and rising material costs, packaging buyers must navigate a complex landscape. The right packaging choices can ease stress on the supply chain, while poor design or sourcing decisions can amplify bottlenecks, drive up costs, and increase product damage. How the Holiday Season Strains Supply Chains Higher order volumes: Warehouses and carriers face peak loads. Material shortages: High demand for corrugated and mailers creates lead time risks. Carrier delays: Overloaded networks increase transit times and handling. Labor constraints: Seasonal staff may have less training in handling. These factors combine to increase both risk and cost for packaging programs Packaging Strategies to Reduce Stress Source early: Secure corrugated, mailers, and all packaging materials before peak demand. Standardize SKUs: Fewer box sizes streamline fulfillment and stocking. Right-size for freight: Reduce DIM charges and optimize pallet loads. Reinforce durability: Stronger boxes prevent returns from mishandling. Flat-pack efficiency: Displays and cartons that ship compactly save space. Balancing Speed and Protection The challenge lies in balancing speed with durability. Overbuilt boxes slow down assembly and inflate costs, while underbuilt packaging risks damage and returns. Buyers must focus on: Identifying high-risk SKUs for reinforced protection. Using inserts or coatings to strengthen vulnerable products. Testing packaging under simulated peak season conditions. The Role of Sustainability in Peak Season Shoppers expect sustainable packaging even during high-volume periods. Supply chain stress is amplified when packaging is overbuilt or wasteful. Using recyclable corrugated or paper-based void fill balances eco goals with functionality. Holiday Packaging Solutions with Brown Packaging Brown Packaging helps brands prepare for peak season by engineering packaging that reduces supply chain stress. From durable corrugated solutions to optimized freight efficiency, our programs balance cost, sustainability, and performance. Contact us to get your packaging supply chain ready for the holidays. References Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.GS1. (2022). Retail Supply Chain Standards for Packaging and Logistics. Retrieved from https://www.gs1.orgUPS. (2023). Holiday Shipping Deadlines and Carrier Capacity Updates. Retrieved from https://www.ups.com (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Ecommerce Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts