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.
RSC boxes are widely used because they balance strength with cost efficiency. But not all RSC boxes are created equal. Buyers have to weigh board grade, flute profile, and design factors to avoid overpaying for unnecessary strength or, worse, underpaying and risking product damage. Understanding these trade-offs ensures that packaging budgets are optimized without compromising protection. Board Grade and Cost Trade-Offs Higher Grades (e.g., 44 ECT) Provide greater stacking strength. Necessary for heavy products, palletized loads, or export packaging. Higher cost due to stronger liners and mediums. Lower Grades (e.g., 26–32 ECT) Ideal for lightweight products. Cost-effective for single-use shipments or direct-to-consumer e-commerce. Reduce material cost but lower compression resistance. Takeaway: Over-specifying board grade adds unnecessary cost. Match strength to actual product weight and stacking requirements. Flute Profiles and Efficiency B-Flute: Good balance of cushioning and stacking strength, widely used in RSC. C-Flute: Higher cushioning, thicker profile, similar cost per unit. E-Flute: Thin profile, less stacking strength but reduces material use and shipping cost for small/light products. Higher cost per unit. Takeaway: Flute choice affects not only performance but also dimensional weight — a critical factor in freight costs. Assembly and Material Costs Tape and Labor: RSC requires tape or glue for sealing, which adds to per-unit cost at scale. Automation: Automated case erectors reduce labor, but box tolerances must be consistent to avoid jams. Material Utilization: RSC has one of the most efficient board utilization rates, reducing waste compared to specialty die-cut mailers. Freight and Storage Efficiency Cube Utilization: Right-sizing RSC dimensions reduces dimensional weight charges. Palletization: Box dimensions affect how many units fit per pallet — poor fit can increase freight by 10–15%. Knock-Down Storage: RSC ships flat, minimizing inbound logistics costs and warehouse space. Buyer Takeaway Use lower board grades for lightweight e-commerce and non-palletized shipments to save cost. Reserve higher grades for industrial, heavy-duty, or export applications. Right-size your RSCs to minimize dimensional weight surcharges. Consider automation compatibility to reduce long-term labor expense. When optimized, RSC packaging isn’t just cost-efficient — it’s a lever for total supply chain savings. References Fibre Box Association. (2023). Corrugated Cost Optimization. https://www.fibrebox.org Association of Independent Corrugated Converters (AICC). (2024). Cost and Efficiency in Corrugated Packaging. https://www.aiccbox.org Robertson, G. (2016). Food Packaging: Principles and Practice (3rd ed.). CRC Press. (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. Regular Slotted Container Facebook Twitter LinkedIn Pinterest Relevant Posts
RSC boxes dominate corrugated packaging, but they aren’t always the best fit. Specialty box styles like Full Overlap (FOL), RETT mailers, and die-cut formats offer unique advantages for certain applications. Understanding when to stay with an RSC versus upgrading to a specialty style ensures buyers balance cost, performance, and presentation. When RSC Is Best Bulk Shipping: Strong compression strength makes RSC ideal for palletized loads. Low Cost: Efficient to manufacture with minimal board waste. Versatility: Works across industries from industrial to retail. Automation-Ready: Standardized design runs smoothly on case erectors and palletizers. When Specialty Boxes Are Better Full Overlap (FOL) Flaps overlap fully, reinforcing the top and bottom. Better for heavy products or shipments that need extra stacking strength. RETT Mailers Dust flaps and cherry locks eliminate tape, improving assembly speed. Ideal for e-commerce and branded unboxing experiences. Die-Cut Boxes Custom shapes and closures for product-specific fit. Useful when presentation and consumer experience are top priorities. Key Trade-Offs Feature RSC Box Specialty Box Styles Assembly Speed Slower (tape required) Faster (die-cut, self-locking) Stacking Strength High Variable (higher in FOL, lower in mailers) Branding Potential Basic Premium (better graphics and unboxing) Flexibility Universal Application-specific Buyer Takeaway Stick with RSC when cost, strength, and scalability matter most. Upgrade to FOL for heavy-duty industrial shipments. Choose RETT or die-cut mailers for e-commerce and premium branding. By evaluating your priorities — strength, speed or presentation — you can decide whether RSC remains the best fit or if specialty box styles deliver added value. References Fibre Box Association. (2023). Corrugated Box Styles and Applications. https://www.fibrebox.org Association of Independent Corrugated Converters (AICC). (2024). Corrugated Design and Performance. https://www.aiccbox.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 Ecommerce Display Foam Printing Protection Retail 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
In the competitive pet care industry, packaging graphics can be as influential as product quality when it comes to driving sales. For pet food, treats, supplements, and accessories, print method and finishing choices impact shelf presence, consumer trust, and brand differentiation. Print Methods for Pet Care Packaging Flexographic Printing How it Works: Uses flexible relief plates and water-based or UV-cured inks. Advantages: Cost-effective for high-volume runs. Suitable for porous and non-porous substrates, including kraft paper, film, and woven polypropylene. Limitations: Lower resolution than gravure for complex imagery. Plate costs make it less ideal for short runs. Digital Printing How it Works: Uses inkjet or toner-based technology without printing plates. Advantages: Ideal for short runs, SKU versioning, and seasonal promotions. No plate costs; faster turnaround. Limitations: Higher per-unit cost for large volumes. Limited ink adhesion on certain films without primers or coatings. Rotogravure Printing How it Works: Uses engraved cylinders to transfer ink directly onto the substrate. Advantages: Exceptional image detail and color consistency. Ideal for full-coverage, high-graphic designs on flexible films. Limitations: High cylinder cost; best for very large production runs. Finishing Techniques for Shelf Impact Matte & Gloss Varnish Combinations: Create contrast that draws attention to logos or product images. Soft-Touch Coatings: Give a premium tactile feel, appealing in higher-end treat or supplement markets. Metallic Inks & Foil Stamping: Provide high-end visual cues, often associated with premium quality. Transparent Windows: Showcase the product while maintaining high-graphic branding around it. Consumer Psychology in Pet Packaging Pet Imagery: Featuring realistic, happy pets increases emotional engagement. Color Selection: Earth tones for natural or organic product positioning. Bright colors for treats or playful product lines. Typography: Bold, legible fonts support quick recognition in busy retail environments. Durability and E-Commerce Considerations Scuff-Resistant Coatings: Prevent graphic wear during transit and shelf handling. Lamination Choices: Protect against moisture, grease, and abrasion for products like kibble and chews. References ASTM International. (2016). ASTM D5264-16: Standard practice for abrasion resistance of printed materials by the Sutherland rub tester. ASTM International. https://doi.org/10.1520/D5264-16ASTM International. (2019). ASTM D685-19: Standard practice for conditioning paper and paper products for testing. ASTM International. https://doi.org/10.1520/D0685-19Packaging Printing Handbook. (2023). Flexography, digital, and gravure printing methods in packaging. Retrieved from https://www.packagingprintinghandbook.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. Pet Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Point-of-purchase (POP) displays do more than attract shoppers—they must also survive the complexities of modern supply chains. From manufacturing and warehousing to transportation and in-store setup, each stage presents risks that can compromise display performance. Addressing these challenges early in design ensures displays not only capture attention on the floor but also arrive intact, compliant, and cost-effective. Manufacturing and Lead Time Constraints POP displays are often tied to seasonal or promotional campaigns with fixed launch dates. Tight lead times create risks such as: Material availability: Shortages of corrugated board, coatings, or inks delay production. Complexity of die-cuts: Intricate designs slow manufacturing efficiency. Volume requirements: High-volume orders may exceed production capacity. To mitigate risks, displays must be designed for manufacturability without compromising branding. Warehousing and Handling Risks Displays frequently move through multiple handling points before reaching retail stores. Poor design choices can lead to: Stacking failures: Weak structural design leads to collapsed units in storage. Space inefficiency: Oversized designs increase warehousing costs. Damage in staging: Displays not built for repeated handling degrade before reaching stores. Transportation Challenges Freight adds another layer of stress on displays. Vibrations, compression, and shifting loads can all cause damage. Key considerations include: Flat-pack shipping efficiency to reduce cube and freight cost. Reinforced edges and coatings to withstand long-haul transit. Pallet compliance to ensure safe and stable shipping. Retailer Compliance Requirements Major retailers impose strict specifications for POP displays. Failing to meet them can result in rejected shipments or costly redesigns. Compliance often covers: Footprint and height limitations. Palletization standards for handling efficiency. Graphics placement for barcode and label visibility. Safety standards for load stability. Strategies to Overcome Supply Chain Challenges Engage structural and graphics teams early for alignment. Test prototypes for strength, compliance, and transit durability. Collaborate with logistics partners to optimize pallet and trailer efficiency. Plan lead times around material availability and peak retail calendars. POP Display Solutions with Brown Packaging Brown Packaging designs POP displays with supply chain realities in mind. From pallet-ready club store displays to compact seasonal promotions, we engineer solutions that balance visual impact with durability and compliance. Contact us to discuss how we can optimize your next display. References Shop! Association. (2021). Best Practices for In-Store Marketing and POP Displays. Retrieved from https://www.shopassociation.orgGS1. (2022). Retail Supply Chain Standards for Packaging and Logistics. Retrieved from https://www.gs1.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. (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
Holiday returns cost retailers billions each year, with packaging failures being a major driver. Damaged goods, oversized boxes, and poor protection lead to dissatisfied customers and costly reverse logistics. For packaging buyers, engineering better holiday packaging is one of the most effective ways to reduce returns and protect profit margins. Why Returns Spike During the Holidays High order volumes: More packages mean more opportunities for failure. Rushed fulfillment: Mistakes in packing increase product damage. Fragile products: Gifts like electronics and glassware need extra care. Customer expectations: Shoppers expect pristine deliveries for gifting. Packaging Strategies to Reduce Returns Right-size design: Prevents product shifting and dimensional weight charges. Protective inserts: Foam, molded pulp, or corrugated dividers secure fragile items. Durability upgrades: Double-wall corrugated for heavy or bulk SKUs. Moisture resistance: Coatings or liners protect against winter weather. Clear labeling: “This Side Up” and handling icons reduce rough handling. The Role of Testing in Return Reduction Packaging validation ensures boxes survive real-world conditions: Compression testing for stacked trailers. Drop testing for rushed warehouse handling. Vibration testing for long-haul shipping. Testing reduces the risk of repeat failures that erode consumer trust. Balancing Cost and Protection Not all SKUs need the same level of packaging reinforcement. Buyers should prioritize: High-value and fragile products. SKUs with past return issues. Items that ship long distances or through multiple carriers. Holiday Packaging Solutions with Brown Packaging Brown Packaging helps brands reduce holiday returns through smarter packaging design and testing. From right-sizing to reinforced corrugated and protective inserts, our solutions protect products and profitability. Contact us to strengthen your holiday packaging program. References International Safe Transit Association (ISTA). (2022). Test Procedures for Packaged Products in Transit.UPS. (2023). Peak Season Returns and Reverse Logistics Report. Retrieved from https://www.ups.comSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. (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 Ecommerce Packaging By submitting your information, you agree to our terms and conditions and privacy policy. Facebook Twitter LinkedIn Pinterest Relevant Posts