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.
Gusseted bags are designed with extra folds of material at the sides or bottom to increase capacity and structural support. This feature makes them ideal for products requiring more volume, weight capacity, or shelf stability. Available in both poly (plastic) and flexible pouch formats, gusseted bags are widely used across food, retail, and industrial markets. Side Gusset Bags Design Additional material on the sides allows expansion for greater volume. Slimmer profile takes up less shelf space compared to bottom gusset designs. Advantages Efficient storage and shipping due to compact shape. Strong capacity for heavier or bulkier products. Limitations Harder to stack neatly for retail displays. Less stable when standing upright compared to bottom gusset bags. Common Applications Coffee and tea Pet food Dry ingredients (flour, rice, grains) Frozen foods Snacks and confectionery Personal care items or textiles Bottom Gusset Bags Design Extra material at the bottom expands outward, allowing the package to stand upright. Offers greater display appeal with more visible front-facing branding. Advantages Excellent stability on shelves and counters. Versatile for liquid, powder, or irregularly shaped products. Limitations Occupies more shelf space compared to side gusset designs. May require stronger sealing for heavier or sharp-edged products. Common Applications Candy and baked goods Coffee and powdered beverages Sanitary and personal care products Pharmaceuticals Liquid products (soups, sauces, supplements) Choosing Between Side and Bottom Gussets The right gusset design depends on product needs, distribution, and retail goals: Side Gusset: Best for products needing compact storage and high-volume capacity with less emphasis on shelf display. Bottom Gusset: Best for stand-up presentation, premium branding, and consumer visibility. Consider whether you need packaging that will be stackable vs. stand-up, space-saving vs. display-ready, and how your graphics or branding will appear on the chosen format. Buyer Takeaway Choose side gusset bags when storage efficiency and capacity are key priorities. Choose bottom gusset bags when branding, display visibility, and consumer presentation matter most. Both styles can be fully customized with graphics, colors, and finishes to support your product and marketing strategy. References Flexible Packaging Association. (2023). Guide to Pouch Formats and Applications. Retrieved from https://www.flexpack.org Robertson, G. L. (2016). Food Packaging: Principles and Practice (3rd ed.). CRC Press. Plastics Industry Association. (2022). Trends in Flexible Packaging. Retrieved from https://www.plasticsindustry.org (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Folding Carton Display Packaging Rigid Box Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Gusset Pouch Facebook Twitter LinkedIn Pinterest Relevant Posts
Pallet optimization is the process of maximizing efficiency in space utilization and handling while minimizing freight costs. It requires strategic use of surface area, stacking height, and protective measures such as corner boards, straps, and stretch film. Effective pallet optimization not only reduces costs but also improves safety, prevents product loss, and ensures compliance with retailer requirements. Why Pallet Optimization Matters Logistics Efficiency: Optimized pallets reduce wasted space in trucks, warehouses, and distribution centers. Cost Reduction: Better space utilization lowers freight expenses by reducing pallet count and dimensional charges. Retail Compliance: Many retailers enforce pallet standards to streamline storage and handling. Safety: Stable pallets minimize risk of shifting loads and workplace accidents. 9 Tips for Pallet Optimization Optimize Packaging Design Structure Select the Right Packaging Material Consider Supply Chain Conditions Place Heavier Objects at the Bottom Stack to the Edge, Not Beyond Use Pallet Optimization Software Keep Edges Straight and Uniform Apply the Correct Stretch Film Strap Down the Pallet if Needed Optimize Packaging Design Uniform, properly sized packaging stacks securely. Avoid oversized cartons, sharp edges, or unnecessary void space that weakens stability and wastes pallet capacity. Select the Right Packaging Material Corrugated strength impacts pallet load stability. Damaged cartons compromise entire stacks. Choose materials that withstand compression, vibration, and environmental stress. Consider Supply Chain Conditions Heat, humidity, cold, and shock affect packaging integrity. Use appropriate protective materials (foam, bubble wrap, anti-static additives) and pallet reinforcements. Place Heavier Items at the Bottom A stable foundation prevents crushing of lighter cartons and reduces shifting risk during transit. Stack to the Edge, Not Beyond Overhanging cartons weaken load stability and may incur additional carrier fees. Align cartons flush with pallet edges. Use Pallet Optimization Software Tools like CAPE, StackBuilder, and Best Pallet provide load simulations to maximize cube utilization and safety. Keep Edges Straight and Uniform Square, even loads distribute weight evenly. Avoid pyramid-style stacking, which destabilizes pallets and reduces efficiency. Apply the Correct Stretch Film Film strength and elasticity should match load weight and configuration. Specialty films with additives can improve performance in challenging conditions. Add Straps if Needed Polypropylene, steel, polyester, or cord straps provide additional stability. Combining strapping with corner boards and slip sheets further improves safety. Benefits of Pallet Optimization Improved Safety: Stable pallets reduce workplace injuries and accidents. Reduced Shipping Costs: Maximizing cartons per pallet lowers freight and fuel expenses. Faster Handling: Uniform stacks improve speed and accuracy during loading and unloading. Product Protection: Properly secured pallets prevent carton damage and inventory loss. Better Space Utilization: Optimized loads maximize warehouse and trailer capacity. Buyer Takeaway Pallet optimization is more than stacking boxes neatly—it’s a supply chain strategy. By optimizing packaging design, material strength, and pallet configurations, businesses can reduce costs, improve safety, and meet retailer requirements. The investment in software, stretch film, or strapping often pays for itself in fewer freight charges and reduced product damage. References International Safe Transit Association (ISTA). (2023). Distribution Testing Standards. Retrieved from https://ista.org Fibre Box Association. (2023). Palletization and Corrugated Packaging. Retrieved from https://www.fibrebox.org Soroka, W. (2016). Fundamentals of Packaging Technology (5th ed.). Institute of Packaging Professionals. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Folding Carton Display Packaging Rigid Box Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Point-of-purchase (POP) displays are designed to capture shopper attention and influence buying decisions. Beyond structure and branding, the quality of print determines how well a display communicates from multiple viewing angles in a retail environment. Selecting the right printing method ensures your display performs both visually and functionally. Printing Methods for Corrugated POP Displays Not all printing methods are suited for corrugated displays. Each has its own strengths and trade-offs in cost, speed, quality, and run size. The three most common methods are: Flexographic Printing Digital Printing Lithographic (Offset) Printing Flexographic Printing Flexographic printing uses plates to apply ink as material passes through rollers. Advantages Cost-Efficient at Scale: Once plates are created, cost per unit is low for large or repeat orders. Pantone Accurate: Ensures precise color matching across production runs. Versatile: Works on uneven surfaces and a wide range of substrates. High Speed: Suited for mass production. Limitations High Startup Costs: Plates and tooling are expensive, making short runs less economical. Poor for Sampling: Costly and impractical to produce prototypes. Best Fit: Large-volume retail displays where consistency and color accuracy are priorities. Digital Printing Digital printing applies artwork directly from a file to the substrate, eliminating plates. Advantages Low Startup Cost: Cost-effective for short runs and prototypes. Fast Turnaround: Ideal for tight deadlines or seasonal campaigns. Flexible: Easily handles multiple SKUs or frequent artwork changes. High Quality: Produces sharp graphics suitable for branded displays. Limitations Less Economical at Scale: Higher cost per unit for large volumes. Color Variability: Approx. 95% accurate; not a perfect Pantone match. Slower Mass Output: Not as efficient as flexographic presses for high quantities. Best Fit: Small-batch retail displays, prototypes, or variable-data campaigns. Lithographic (Offset) Printing Lithographic printing transfers ink from a plate to a rubber blanket, then onto the substrate, with options for coatings or varnishes. Advantages Highest Quality: Sharp, detailed graphics with accurate color reproduction. Premium Finishes: Coatings and varnishes enhance durability and appearance. Scalable: Handles small to large format prints. Limitations High Setup Cost: Plates and setup make short runs expensive. Not Sample-Friendly: Prototypes are cost-prohibitive. Longer Lead Time: Setup and adjustments require planning. Best Fit: High-volume displays where premium image quality is essential for brand impact.` Designing Graphics for POP Displays Effective POP displays combine structure with clear, impactful graphics. Common elements include: Logos and Brand Colors Product Imagery Text (ingredients, instructions, contact info) Symbols and Icons Promotions or Pricing Call-to-Action Messaging Mascots or Characters Any artwork provided must be adjusted to fit dielines correctly. Designers ensure bleed, folds, and structural features align with graphics to avoid misprints. Choosing the Right Printing Method When selecting a printing process, consider: Quality: Lithographic offers the highest resolution; flexographic is durable but less detailed. Budget and Quantity: Flexographic suits large runs, digital works best for small runs, lithographic for high-volume premium graphics. Lead Time: Digital is fastest due to no plate requirements. Brand Goals: For premium retail impact, lithographic justifies higher cost; for efficiency, flexographic is the workhorse. Buyer Takeaway Use flexographic printing for large-scale runs that need durability and consistent Pantone colors. Choose digital printing for prototypes, short runs, or campaigns with multiple SKUs. Invest in lithographic printing for premium displays that require sharp, high-quality graphics. Selecting the right method ensures POP displays not only stand out visually but also align with budget and timeline requirements. References Association of Independent Corrugated Converters (AICC). (2024). Printing Methods in Corrugated Packaging. Retrieved from https://www.aiccbox.org Flexible Packaging Association. (2023). Digital vs. Flexographic Printing. Retrieved from https://www.flexpack.org Robertson, G. L. (2016). Food Packaging: Principles and Practice (3rd ed.). CRC Press. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Folding Carton Display Packaging Rigid Box Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. POP Displays Facebook Twitter LinkedIn Pinterest Relevant Posts
For those uninitiated in the finer points of storage and organization, corrugated bin boxes might sound like an odd focal point. However, for hardware stores, these simple cardboard constructions prove indispensable. Let’s dive into the reasons why corrugated bin boxes are essential for hardware stores. Robust Durability At the core of their popularity, corrugated bin boxes boast a unique construction. Comprising ridges and grooves, this type of cardboard is both lightweight and sturdy. Given the diverse range of tools and hardware that need storage – from screws and nails to brackets and bolts – it’s pivotal for storage solutions to be durable. Corrugated boxes fit the bill perfectly. Efficient Organization Hardware stores are known for their myriad small parts. Without a system, these items can become a jumbled mess, making inventory a nightmare and shopping an arduous task for customers. Corrugated bin boxes offer an easy and straightforward way to categorize and organize these small items. Labelled properly, these boxes can help customers find what they need without much hassle. Customizable Sizes Given the variation in hardware sizes and quantities, flexibility in storage size is a must. Corrugated bin boxes come in an array of sizes, ensuring that there’s always a right fit for the item in question. Furthermore, the ease with which they can be folded, reshaped, or even combined offers dynamic solutions for changing inventory needs. Cost-Effective Unlike metal or plastic storage bins, corrugated bin boxes are relatively inexpensive. For hardware stores, particularly those just starting out or working with limited capital, this is a major plus point. The lower costs don’t translate to a compromise in quality either; these boxes offer reliable storage without breaking the bank. Eco-Friendly In a world that’s becoming increasingly eco-conscious, corrugated bin boxes offer an advantage over some other storage alternatives. Made primarily from recycled paper, they’re biodegradable. Hardware stores can tout their green credentials by choosing this environmentally friendly storage solution. Space Optimization Corrugated bin boxes can be easily stacked or arranged in a way that maximizes floor space. This is particularly useful for smaller hardware stores or those in premium locations where every square foot counts. Instead of bulky shelves or cabinets, these boxes can be efficiently arranged to create a clean, organized look, making the most out of limited space. Enhanced Aesthetics With the option to print, paint, or design these boxes, hardware stores can enhance their branding or simply create a more appealing aesthetic for their aisles. A well-organized, clean, and branded environment can significantly enhance customer experience. Safety Sharp objects like nails, screws, or other hardware can pose risks if not stored properly. Corrugated bin boxes ensure that such items are safely contained, preventing accidents in the store. Conclusion Corrugated bin boxes, though simple, bring a slew of benefits to the table for hardware stores. From organization and durability to eco-friendliness and cost savings, these humble storage solutions punch well above their weight. It’s no wonder that they remain an indispensable part of the hardware store landscape. If you are interested in corrugated bin boxes, then partner with Brown Packaging today to get started. (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. Bin Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts
In today’s competitive marketplace, it’s not enough for a product to be high-quality; it must also provide an exceptional experience from the moment it arrives at the customer’s doorstep. Much like the principles of User Experience (UX) design, creating an engaging and memorable unboxing experience is crucial. We’ve adapted Peter Morville’s UX Honeycomb to create a Custom Packaging Honeycomb, which comprises seven essential factors for designing the perfect unboxing experience. Anticipation Engagement Discovery Memorability Shareability Personalization Sustainability Anticipation: Building Excitement Before the box is even opened, the unboxing experience should begin by generating anticipation. Consider the use of eye-catching visuals on the packaging, teasing what’s inside, and creating a sense of excitement. Think about Apple’s iconic product packaging; it teases the product within, leaving customers eager to explore further. Engagement: Holding Attention A great unboxing experience should be engaging, holding the customer’s attention throughout. Use creative design, storytelling, or interactive elements within the packaging to keep customers captivated. Brands like Glossier use colorful packaging and personalized notes to maintain engagement, making customers feel special. Discovery: Easy Exploration Customers should easily discover and explore the different layers, compartments, or elements of your packaging. Hidden surprises or information should be intuitively found, adding an element of delight. Memorability: Leave a Lasting Impression A memorable unboxing experience stays with customers long after they’ve opened the box. Aim to create an experience that’s shareable and worth remembering, fostering brand loyalty. Luxury brands like Tiffany & Co. have mastered the art of creating memorable unboxing experiences, from the signature blue box to the white satin ribbon. Shareability: Encourage Social Sharing Leverage the power of social media by designing an unboxing experience that’s shareable. Encourage customers to snap pictures or record videos of their unboxing moments, spreading brand awareness. Beauty companies like Sephora design packaging that customers love to share on Instagram, expanding their reach organically. Personalization: Tailor to the Individual Whenever possible, personalize the unboxing experience for each customer. This could include handwritten notes, customized packaging, or product recommendations based on their preferences. Sustainability: Mindful of the Environment In an era of growing environmental awareness, sustainable packaging practices are essential. Use eco-friendly materials and provide clear instructions on how to recycle or reuse the packaging. Brands like Patagonia are known for their commitment to sustainability, extending it to their packaging materials. Conclusion The Custom Packaging Honeycomb provides a framework for creating unboxing experiences that delight customers and strengthen brand loyalty. By incorporating these seven factors – anticipation, engagement, discovery, memorability, shareability, personalization, and sustainability – brands can ensure that the unboxing experience is as exceptional as the product itself. As the e-commerce landscape continues to evolve, remember that the unboxing experience can be a powerful tool for setting your brand apart and leaving a lasting impression on customers. If you are interested in custom packaging, then partner with Brown Packaging today to get started. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce Design Foam Folding Carton Packaging Plastic Packaging Pouch Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts