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.
A Full Overlap (FOL) box is a type of corrugated shipping box where the flaps fully overlap each other when closed, providing additional strength and durability. Unlike regular slotted containers (RSCs), FOL boxes have double-layered protection on the top and bottom, making them ideal for heavy, bulky, or fragile items. This structural design enhances stacking strength, impact resistance, and overall box integrity, reducing the risk of damage during transit and storage. Why Full Overlap Boxes are Ideal for Bike Packaging Bikes require durable, impact-resistant packaging to ensure they arrive undamaged, whether shipped to retailers, distributors, or customers. A Full Overlap Box provides superior protection against crushing, punctures, and rough handling. Here’s why they are the preferred choice for bike packaging: Increased Strength & Durability – The overlapping flaps create a reinforced structure, preventing crushing and minimizing movement inside the box. Added Protection for Fragile Components – Bikes have delicate parts like gears, chains, and brake systems that require extra care during shipping. Enhanced Stacking Capability – FOL boxes handle vertical pressure better, making them ideal for warehouse storage and bulk shipments. Custom Fit & Inserts Available – These boxes can be designed with custom inserts and foam padding to keep bike parts securely in place and prevent shifting. Eco-Friendly & Sustainable – Many FOL boxes are made from recycled materials and can be fully recyclable, aligning with sustainability goals. Customizing Full Overlap Boxes for Bikes To provide maximum protection and branding, Full Overlap Boxes can be customized to fit specific bike models and shipping needs. Some key customization options include: Size & Structure Customization Designed to fit various bike sizes, from road bikes to mountain bikes. Can include double-wall or triple-wall corrugated material for added protection. Reinforced edges and custom cut-outs for better handling. Protective Inserts & Cushioning Foam padding and corrugated inserts to keep the bike frame and parts from moving. Dividers for accessories like pedals, seats, and handlebars. Shock-absorbing corner protectors to reduce impact damage. Branding & Printing Options Custom printing for logos, handling instructions, and product details. Lithographic, flexographic, or digital printing to match branding requirements. Matte or gloss finishes for a premium look. The Shipping & Storage Advantages of FOL Bike Boxes When shipping bikes, damage prevention and cost efficiency are top priorities. Full Overlap Boxes help optimize shipping in the following ways: Easier Palletization & Secure Stacking – Their rigid structure allows for safe stacking on pallets, reducing wasted space and ensuring safe transit. Reduced Shipping Damage – The extra layers of corrugated flaps absorb shock and pressure, lowering the chance of returns due to damage. Better Handling for Warehouses & Retailers – Reinforced hand holes or built-in grip areas can be added for easier transport. Flat-Pack Storage Efficiency – Unassembled boxes take up minimal space until needed, making inventory storage easier. Conclusion: Why Full Overlap Boxes Are the Best Choice for Bikes For businesses in the cycling industry, choosing the right packaging can make a significant difference in product safety, customer satisfaction, and shipping efficiency. Full Overlap Boxes provide maximum protection, superior stacking strength, and customizable features that cater specifically to bike packaging needs. Whether you’re shipping single bikes to customers or bulk orders to retailers, these boxes offer a reliable, cost-effective, and sustainable packaging solution. Need a custom Full Overlap Box for your bikes? Contact Brown Packaging today to discuss your packaging requirements and let our experts create the perfect solution for you! (714)300-0650 request@brownpackaging.com Most Recent Posts: Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Bike Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Protein bars are a popular on-the-go snack, requiring durable, protective, and visually appealing packaging to ensure freshness and convenience. The right packaging helps extend shelf life, maintain texture, and protect against contamination, making it essential for both retail and eCommerce sales. Businesses must carefully select the best materials and formats for their protein bars to optimize product protection and brand visibility. Types of Packaging for Protein Bars Protein bars can be packaged in various materials and formats depending on brand preference, shelf life requirements, and distribution channels. The most common types include: Flexible Film Packaging (Flow Wraps & Roll Stock) Flow wrap packaging, often produced from roll stock, is the most widely used solution for protein bars due to its lightweight, cost-effectiveness, and superior protection. It consists of a plastic or foil-based flexible film, heat-sealed to create an air-tight package. Benefits: Provides moisture and oxygen barrier to extend shelf life. Offers high-speed packaging efficiency for mass production. Allows for vibrant branding and print customization. Stand-Up Pouches and Resealable Bags Ideal for multi-pack protein bars, stand-up pouches provide convenience and branding appeal while protecting bars from crushing and environmental factors. Benefits: Resealable options improve freshness and portion control. Provides a premium look for retail shelves and club store formats. Customizable with clear windows, matte or gloss finishes, and tear notches. Folding Cartons Many protein bars are sold in multi-bar packs housed in folding cartons. These secondary packaging solutions enhance shelf presence and provide additional protection. Benefits: Ideal for bulk packaging and organized retail display. Supports branding with high-quality printing and embossing options. Adds structural protection to prevent crushing. Corrugated Boxes for Shipping For wholesale distribution and eCommerce fulfillment, protein bars are often packed in corrugated shipping boxes to ensure safe transit and bulk handling. Benefits: Provides durability for long-distance shipping and warehouse storage. Can be designed with custom inserts for product security. Custom printing allows for branded unboxing experiences. POP and Countertop Displays Retailers often use point-of-purchase (POP) and countertop displays to showcase protein bars in high-traffic areas. These displays help drive impulse purchases and enhance brand visibility. Benefits: Designed for maximum visibility in checkout lanes and retail aisles. Can be customized for seasonal promotions or new product launches. Available in corrugated or folding carton formats for easy setup. Key Packaging Considerations for Protein Bars Choosing the right protein bar packaging requires evaluating several factors: Shelf Life Protection: Packaging must offer barrier properties against moisture, air, and light to prevent spoilage. Consumer Convenience: Features like resealable closures, easy-open tear notches, and portability enhance the user experience. Branding & Marketing Appeal: High-quality printing, embossing, or matte/gloss finishes make a product stand out on retail shelves. Shipping & Retail Optimization: Bulk packaging and display solutions improve storage, handling, and in-store presentation. Final Thoughts: Selecting the Best Protein Bar Packaging Protein bar packaging should be protective, convenient, and visually appealing while aligning with industry requirements. Whether using flow wraps and roll stock for single bars, folding cartons for multi-packs, corrugated boxes for shipping, or POP displays for retail, businesses should evaluate their packaging based on functionality, branding, and distribution needs. Looking for custom protein bar packaging solutions? Contact Brown Packaging today to explore innovative packaging options that meet your brand’s needs! (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. Protein Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
For mid-sized businesses, packaging is a crucial element that impacts brand identity, operational efficiency, and customer experience. Unlike small businesses, which focus on cost-effectiveness, and large corporations, which prioritize mass production, mid-sized companies need a balance of scalability, flexibility, and affordability. With growing competition and shifting market demands in 2025, a strong packaging strategy can help mid-sized businesses improve efficiency, maintain brand consistency, and optimize costs. Key Packaging Considerations for Mid-Sized Businesses Cost-Effective Scaling Without Overproduction Mid-sized businesses must carefully scale their packaging production without overspending. This requires: Right-sizing packaging to eliminate wasted materials and reduce shipping costs. Flexible minimum order quantities (MOQs) to avoid excessive inventory storage. Leveraging hybrid production models, combining stock packaging for standard products and custom packaging for premium lines. Streamlining Supply Chain and Inventory Management Efficient supply chain management ensures consistent packaging availability while preventing overstocking or shortages. Strategies include: Partnering with reliable domestic suppliers to minimize lead times and supply disruptions. Using just-in-time (JIT) inventory models to reduce storage costs. Implementing digital inventory tracking systems to monitor stock levels and order packaging efficiently. Balancing Customization with Production Efficiency Mid-sized businesses need packaging that reflects their brand identity while remaining cost-effective. Best practices include: Using digital printing for small batch orders and frequent design changes. Standardizing core packaging elements (box styles, materials) to reduce production costs. Exploring modular packaging designs that allow for brand differentiation without excessive SKU variations. Enhancing Brand Presentation and Consumer Experience Well-designed packaging helps mid-sized businesses stand out and build brand loyalty. Key considerations include: High-quality print finishes to enhance shelf appeal. Custom inserts and protective elements to improve product security and customer experience. Easy-to-open designs that simplify unboxing while reducing damage rates. Sustainability Without Excessive Costs Sustainable packaging is becoming increasingly important, but cost remains a concern for mid-sized companies. Practical solutions include: Choosing lightweight, recyclable materials to lower shipping costs and meet sustainability goals. Using minimalist packaging designs to reduce material waste. Exploring compostable or biodegradable options without drastically increasing production costs. Adapting to Omnichannel Distribution Needs Many mid-sized businesses sell both in-store and online, requiring packaging that works for multiple channels. Strategies include: Designing packaging for both eCommerce and retail to streamline production. Using protective yet lightweight packaging to reduce return rates and shipping fees. Incorporating QR codes and digital touchpoints for customer engagement across platforms. Final Thoughts: The Mid-Sized Business Packaging Strategy for 2025 For mid-sized businesses, packaging must strike a balance between cost-efficiency, brand appeal, and operational flexibility. By optimizing supply chains, leveraging smart printing methods, and focusing on scalable customization, companies can position themselves for growth in 2025. Looking for tailored packaging solutions for your mid-sized business? Contact Brown Packaging today to explore cost-effective and innovative options. (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 Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Packaging isn’t just a box or a bag—it’s a line item on your budget, a touchpoint with your customer, and a critical part of your supply chain. But what many companies don’t realize is that their packaging may be costing them more than it should—not just in materials, but in storage, shipping, damage, and customer experience. If you haven’t taken a close look at your packaging setup lately, now’s the time to assess whether it’s helping or hurting your bottom line. Oversized Packaging = Wasted Money It’s a common mistake: using a box that’s much larger than the product. Not only does this require more void fill, it also increases your dimensional shipping weight, which drives up freight costs—especially for e-commerce and parcel shipping. Solution:Switch to right-sized packaging or explore mailer alternatives like poly mailers or custom die-cut corrugated options that hug the product more closely. Over-Engineering Without Added Benefit It’s easy to assume stronger means better—but not every product needs double-wall corrugated, high-end inserts, or expensive finishes. If your packaging is doing more than it needs to, you’re likely paying for protection or features your customer doesn’t notice or value. Solution:Review your structural design and board grade. A packaging engineer can help you optimize for the product’s weight and fragility without overspending on material. Inefficient Packaging Leads to Higher Labor Costs Packaging that’s hard to assemble, overcomplicated, or inconsistent can slow down fulfillment and increase errors. Solution:Use auto-lock bottom boxes, pre-folded cartons, or streamlined assembly instructions to reduce pack time, labor cost, and error rates. Your Shipping and Fulfillment Costs Are Rising Higher freight bills or warehouse inefficiencies are often tied to inefficient packaging: oversized boxes, time-consuming assembly, or mismatched pallets. Why it matters:This is the moment to reallocate budget toward structural redesign or automation-friendly packaging that reduces labor, materials, and dimensional weight. Storage and Shipping Inefficiencies If your packaging takes up too much warehouse space or doesn’t palletize efficiently, you’re losing money in storage and shipping before a product even leaves your facility. Solution:Work with your supplier to optimize dimensions for palletization and warehouse stacking. You may be able to reduce total storage volume or fit more units per shipment. Damage and Returns Are Killing Margins If your packaging fails in transit—even occasionally—the cost of returns, replacements, and negative reviews can quickly outweigh the cost of upgrading your packaging. Solution:If you’re seeing damage or breakage rates over 1–2%, it’s time to audit your box strength, inserts, and material choices. Improving packaging here is a direct path to better margins. Missed Opportunities with Branding Generic packaging may be cheaper—but it can cost you in brand recognition, customer loyalty, and perceived value. If your packaging doesn’t reflect your product quality, customers may assume it’s lower value. Solution:Consider affordable branding upgrades like one-color flexo print, interior printing, or custom labels to make a stronger impression without blowing the budget. Final Thoughts If you’re only looking at unit cost when reviewing packaging, you’re missing the bigger picture. True packaging costs include materials, shipping, labor, storage, damage, and brand perception. Ready to find out if your packaging is costing more than it should?We’ll help you audit your current setup and identify opportunities to save money—without compromising quality, protection, or your customer experience. (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 Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Before a customer ever opens your product, they’ve already formed an opinion—based on the packaging. Whether you’re in retail, e-commerce, or B2B, packaging is more than protection—it’s a powerful tool that communicates value, trust, and identity. From visual design and material quality to tactile feel and structural integrity, packaging influences how customers perceive your brand in just seconds. Here’s how, and why it matters. First Impressions Are Built on Packaging Packaging is often the first physical interaction a customer has with your brand. In that moment, the quality of materials, color choices, and overall presentation set expectations about the product inside. Cheap, flimsy packaging can signal low value—even if the product is great Clean, well-structured packaging gives off professionalism and care Premium textures or unique unboxing experiences create anticipation and excitement Consumers don’t just see packaging—they feel it. And those feelings guide how much they trust your product and your brand. Packaging Design Reinforces Brand Identity Your packaging is a reflection of your brand’s personality. Through font, layout, imagery, and finish, it tells the customer what you stand for: Minimalist designs communicate elegance, simplicity, or sustainability Bold graphics signal confidence, creativity, or playfulness Natural materials or kraft board suggest eco-consciousness and authenticity A consistent design system across your SKUs builds recognition and loyalty. Packaging doesn’t just carry your product—it carries your message. Packaging Suggests Product Value Customers often associate the quality of packaging with the quality of the product—even before trying it. This is especially true for high-consideration purchases like: Cosmetics and skincare Supplements and wellness Electronics and accessories Food and beverage A well-designed folding carton or rigid box with premium print and finish instantly elevates perceived value. Even in cost-conscious markets, thoughtful packaging design can justify higher price points. Unboxing Is a Marketing Opportunity In the age of social media, your packaging can become part of the product experience. Branded interiors, clean insert layouts, and satisfying openings turn ordinary shipments into memorable moments—often shared online. The more enjoyable the unboxing, the more likely your customer is to: Recommend your product Leave a positive review Reorder from your brand Post content that builds organic reach In other words, packaging can drive engagement and brand exposure—with zero additional ad spend. Functional Design Builds Trust At the end of the day, packaging must do its job. If it breaks, doesn’t protect the product, or looks messy on arrival, consumer trust takes a hit. Durable corrugated mailers protect during shipping Smart inserts reduce damage and returns Clear labeling and tamper-evident features reassure buyers Easy-open designs improve convenience and satisfaction Good packaging shows your customer that you’ve thought about their experience—and that builds brand credibility. Final Thoughts Consumer perception doesn’t start with your product—it starts with the box, pouch, or carton it comes in. Great packaging tells a story, creates emotion, and strengthens loyalty. It’s one of the most effective tools your brand has—and one of the easiest to get wrong. Looking to improve your packaging strategy?We’ll help you align structure, design, and function to create packaging that connects with your audience and sets your brand apart. (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 Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts