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.
Selecting the right board option for your packaging needs is critical to ensuring product protection, cost efficiency, and customer satisfaction. However, with various materials and specifications available, it can be challenging to decide which is best suited for your products. This guide breaks down the key differences between board options, including thickness, weight, color (kraft vs. white vs. Kemi), and strength (stacking vs. bursting), to help you make informed choices. Key Factors to Consider When Choosing Board Options Thickness and Weight The thickness and weight of your board directly impact the durability and cost of your packaging. Single-Wall Corrugated: Ideal for lightweight products; cost-effective and space-saving. Double-Wall Corrugated: Provides additional durability for heavier or more fragile items. Triple-Wall Corrugated: Offers maximum strength for industrial or bulk shipments. Weight Classifications (measured in pounds per thousand square feet): 26 ECT (Edge Crush Test): Common for lightweight items. 32 ECT: Standard for shipping boxes. 44 ECT: Provides added strength for heavier goods. Pro Tip: Higher ECT ratings or thicker boards are better for products requiring long shipping routes or frequent handling. Kraft vs. White vs. Kemi The color and surface type of your board affect its appearance, branding potential, and environmental impact. Kraft Board: Natural, unbleached brown board. Eco-friendly and cost-effective. Popular for brands emphasizing sustainability. White Board: Provides a clean, polished look. Ideal for high-quality printing and branding. Slightly higher cost due to added processing. Kemi Board: A premium option with a clay-coated surface. Superior for high-quality graphics and moisture resistance. Often used in food packaging or high-end retail boxes. Pro Tip: Kraft is a great choice for eco-conscious brands, while white or Kemi boards work best for visually appealing, printed designs. Stacking Strength vs. Bursting Strength Board strength is measured in two key ways, and understanding the difference is crucial for selecting the right material for your needs. Stacking Strength (Edge Crush Test – ECT): Measures a box’s ability to withstand compression when stacked. Ideal for vertical storage or heavy stacking in transit. Bursting Strength (Mullen Test): Measures resistance to punctures or tears. Better for products that might face rough handling or impact during shipping. Pro Tip: If you’re shipping lightweight items in large quantities, prioritize stacking strength. For fragile or high-value items, bursting strength is more critical. Comparing Board Options Feature Single-Wall Corrugated Double-Wall Corrugated Triple-Wall Corrugated Thickness Light Medium Heavy Weight Capacity Up to 65 lbs 65–95 lbs 95–300 lbs Common Use Cases Apparel, lightweight items Electronics, fragile goods Industrial equipment, bulk items Cost Low Medium High Selecting the Right Board for Your Needs Product Protection Needs For lightweight products: Single-wall corrugated with 32 ECT. For heavy or fragile items: Double-wall corrugated or higher ECT. For high-value items: Triple-wall corrugated or Kemi board with enhanced burst strength. Branding and Visual Appeal For a natural look: Kraft board. For premium branding: White or Kemi boards with gloss or matte finishes. Environmental Considerations For eco-conscious brands: Kraft board with recycled content. For durability with sustainability: Boards with high post-consumer recycled content. FAQs About Board Options Stacking strength measures a box’s ability to withstand vertical pressure, while bursting strength evaluates its resistance to punctures or tears. When should I choose Kemi over white or kraft? Kemi board is ideal for applications requiring superior graphics and moisture resistance, such as food or luxury packaging. How do I balance cost and durability? Consider your product’s weight and shipping needs. Single-wall corrugated is cost-effective for lightweight items, while double-wall is better for heavier goods. Conclusion Choosing the right board option involves balancing your product’s protection needs, branding goals, and budget. Whether you’re deciding between kraft and white or evaluating strength requirements, understanding these factors will help you select the perfect packaging solution. Need expert advice on board materials? Contact us today for tailored recommendations that meet your durability, branding, and budget goals! (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
Launching a product or redesigning packaging can be a significant investment. To minimize risk and gather actionable insights, small packaging runs are a smart way to test the market. This approach allows businesses to gauge consumer reactions, refine designs, and optimize functionality before committing to large-scale production. Here’s how small packaging runs can drive success and why digital production is often the ideal method for this purpose. Why Test with Small Packaging Runs? Minimized RiskBy starting with a small batch, businesses can test packaging concepts without a large financial commitment. This ensures that only well-received designs move forward to full-scale production. Market ValidationTesting in the real world—through focus groups, pop-up shops, or limited releases—provides valuable feedback on packaging design, labeling, and usability. This helps identify what resonates with your audience. Iterative DesignSmall runs allow for adjustments and multiple rounds of testing. Based on feedback, businesses can tweak designs, materials, or messaging to create a more polished final product. Cost-Effective ExperimentationCompared to mass production, small runs are significantly less expensive. This makes it possible to try out multiple designs or features without incurring substantial costs. Why Digital Production is Ideal for Small Runs No Setup CostsTraditional printing methods, like offset printing, require expensive setup processes such as plate creation. Digital printing eliminates these costs, making it cost-efficient for small batches. Faster TurnaroundDigital production enables quick printing and delivery, perfect for tight deadlines or rapid testing cycles. High-Quality OutputModern digital printing delivers sharp, vibrant results, ensuring test packaging looks professional and consistent with final production runs. Flexibility With digital production, you can easily modify designs between runs to test different elements like colors, layouts, or messaging. Key Considerations for Effective Testing Sample Size: Ensure your test batch is large enough to yield statistically significant results. Data Collection: Use multiple methods like online surveys, in-person interviews, or sales performance data to gather insights. Adaptability: Be prepared to adjust your design based on feedback to ensure your packaging aligns with customer expectations. Benefits of Testing with Small Runs Advantage Explanation Cost Savings Avoid overproduction and reduce the risk of investing in a design that doesn’t work. Customer Insights Direct feedback helps identify strengths and weaknesses in your packaging design. Agility Quickly implement changes without the delay or expense of large-scale production. Reduced Environmental Impact Produce only what you need, minimizing waste and resources. Real-World Application: Split Testing for Packaging Split testing, or A/B testing, is a powerful strategy for packaging design. By creating two or more versions of your packaging, you can compare their performance in the marketplace. Examples include: Testing different color schemes or logos. Comparing headline copy or product descriptions. Experimenting with eco-friendly materials versus traditional ones. This iterative process ensures your packaging is always optimized for customer appeal and performance. Conclusion Testing the market with small packaging runs is a low-risk, high-reward strategy for businesses looking to launch new products or redesign packaging. By leveraging digital production for these runs, you gain the flexibility to experiment, refine, and validate designs before committing to large-scale production. Ready to test your packaging? Contact us today to explore digital production solutions tailored to your small-run 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. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Gaylord containers are large, sturdy boxes used primarily for shipping, storing, and handling bulk materials. Often utilized in industries like manufacturing, agriculture, and retail, these versatile containers are designed to accommodate large volumes of products while providing robust protection. Depending on the specific application, Gaylord containers are available in single, double, and triple wall options, each offering varying degrees of strength and durability. In this blog, we will explore the differences between these options and their practical applications. What Are Gaylord Containers? Gaylord containers, also known as bulk bins or pallet boxes, are large corrugated boxes designed for storing and transporting bulk goods. They are typically mounted on pallets for easy handling with forklifts and other equipment. These containers are highly versatile, accommodating a wide range of materials, including powders, granules, parts, and even irregularly shaped items. Single Wall Gaylord Containers Construction: Single wall Gaylord containers consist of one layer of corrugated cardboard. This layer typically includes a fluted sheet sandwiched between two flat linerboards. Applications: Single wall containers are suitable for lighter materials or products that do not require extensive protection during shipping. They are commonly used for: Lightweight products like plastic parts or textiles Non-fragile items that are not prone to damage Short-distance shipping where minimal handling occurs Benefits: Cost-effective solution for bulk packaging Lightweight and easy to handle Efficient for low-risk, high-volume shipping Double Wall Gaylord Containers Construction: Double wall Gaylord containers feature two layers of corrugated cardboard, providing increased strength and durability compared to single wall options. Applications: Double wall containers are ideal for heavier or more delicate items that require extra protection. Common uses include: Metal parts, automotive components, or hardware Products requiring additional cushioning and support Moderate to long-distance shipping with multiple handling points Benefits: Enhanced strength and durability for heavier loads Better protection against impact and compression Suitable for stacking and efficient space utilization Triple Wall Gaylord Containers Construction: Triple wall Gaylord containers are constructed with three layers of corrugated cardboard, offering maximum strength and resistance to external pressures. Applications: These containers are best suited for the heaviest and most fragile items, providing superior protection during transit and storage. They are often used for: Heavy industrial components or machinery parts Fragile items like glassware or electronics Export shipping, where containers face prolonged handling and rough conditions Benefits: Maximum protection for heavy and fragile goods Optimal for international shipping and storage in harsh environments High resistance to punctures, compression, and impact Choosing the Right Gaylord Container Selecting the appropriate Gaylord container depends on several factors: Weight of Contents: Heavier items require double or triple wall containers for adequate support. Fragility: Fragile products benefit from the added protection of multiple wall layers. Distance and Handling: Longer shipping distances and frequent handling call for stronger container options. Budget Considerations: Single wall containers offer cost savings for less demanding applications, while double and triple wall containers are investments in product safety. Customization and Additional Features Gaylord containers can be customized to meet specific needs, including: Printing and branding for enhanced visibility Coating for moisture resistance Lids and liners for additional protection Dividers and inserts for organized storage Conclusion Gaylord containers are essential for industries requiring efficient and secure bulk packaging solutions. By understanding the differences between single, double, and triple wall options, businesses can choose the right container to protect their products, optimize shipping efficiency, and reduce costs. Whether you need basic packaging for lightweight items or robust protection for heavy machinery, Gaylord containers offer a versatile and reliable solution for all your bulk packaging 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. Custom Gaylord Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts
Why Board Grade Selection Matters In today’s volatile supply chain environment, packaging failures aren’t just a nuisance—they’re a liability. Damage in transit, product returns, and load instability all lead back to one foundational element: board grade. Whether you’re shipping across the country or staging products for long-term storage, the right corrugated board strength directly impacts product integrity, compliance, and bottom-line efficiency. Understanding Board Grade Classifications Corrugated board grade is defined by its burst strength (measured in pounds), edge crush test (ECT) rating, or basis weight in pounds per 1,000 square feet. The two most common standards: Mullen Test (Burst Strength): Measures resistance to puncture or rupture under pressure (e.g., 200#). Edge Crush Test (ECT): Measures stacking strength and compression resistance along the edge (e.g., 32 ECT). Higher board grades offer greater durability but come at a cost—so matching board performance to supply chain risk is key. How Board Grade Supports Supply Chain Resilience ✔ Reduces Transit DamageHeavier board grades (like 44 ECT or 275#) are essential for heavier items or mixed-pallet shipping. They prevent crushing under load and protect high-value products from collapse or impact. ✔ Improves Stacking StabilityIf your supply chain includes warehousing, transloading, or racking, poor stacking strength leads to bottom-box failures. ECT-rated boxes offer predictable stacking loads, enabling more reliable palletization strategies. ✔ Adapts to Environmental StressorsIn humid or high-temperature zones, lower-quality board can warp or delaminate. Upgrading to moisture-resistant coatings or wax-treated grades extends package integrity in unpredictable conditions. ✔ Meets Carrier and Retailer ComplianceMajor carriers and retailers (e.g., Amazon, Walmart) often require packaging that meets minimum board grade thresholds for specific product categories. Failing to comply can result in chargebacks or denied loads. Matching Board Grade to Application Lightweight Goods (<30 lbs): 32 ECT or 200# is often sufficient for controlled distribution. Midweight/Stacked Goods (30–65 lbs): 44 ECT or 275# single-wall offers better stability. Heavy or Fragile Items: 48 ECT+, 350# double-wall, or even triple-wall is standard for machinery, appliances, or multi-SKU master packs. Export Shipments: Double-wall with moisture resistance is critical for sea containers and extended transit. Why Resilience Now Means Cost Efficiency Later Skimping on board grade may reduce material costs short-term, but it increases risks throughout the supply chain: Higher damage rates Increased return logistics More manual rework at DCs Lower pallet efficiency By engineering packaging with the right board spec, brands can build flexibility into distribution—whether absorbing shock during LTL shipping or maintaining load stability during storage. Final Thoughts Your corrugated board grade isn’t just a spec—it’s a strategic decision that drives supply chain resilience. From minimizing product loss to meeting compliance and stacking standards, choosing the right board means fewer disruptions and greater operational continuity. At Brown Packaging, we help businesses select, test, and implement the right corrugated materials based on real-world demands. (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
Why Holiday Fulfillment Demands Precision The holiday season introduces a unique set of pressures across the packaging and supply chain landscape—especially for businesses managing kitting, packouts, display builds, or co-packing services. Between condensed retail calendars, last-minute promotional pushes, and compressed logistics windows, fulfillment must shift from a support function to a strategic asset. For manufacturers, brand owners, and retailers, the ability to deliver complete, shelf-ready packaging at scale is the difference between capturing seasonal revenue or missing key market opportunities. What makes this time so complex isn’t just volume—it’s configuration. Packaging fulfillment during the holidays often involves: Multi-SKU kitting (e.g., bundling accessories with electronics) Retail display assembly (quarter pallets, PDQs, club store displays) Gift pack co-packaging (personal care sets, food samplers) Custom print alignment across SKUs and inserts Retailer-specific compliance (labeling, orientation, EDI, GTIN/UPC) These tasks require a fulfillment partner that understands not just packaging mechanics, but retail logistics, promotional timing, and downstream handling constraints. Lead Time Compression and Q4 Logistics Constraints Planning for Q4 fulfillment can’t begin in Q4. By late September, most contract packagers and display fulfillment centers are already operating at or near capacity. Display board lead times stretch, labor is reallocated to high-volume clients, and transportation bottlenecks can ripple back through the supply chain. Businesses that haven’t secured fulfillment commitments by then risk: Extended production turnarounds Higher expedited freight costs Noncompliance with delivery windows Disruption to promotions tied to specific dates Early planning ensures access to labor, materials, and floor space—especially critical for labor-intensive programs that involve manual assembly, complex sequencing, or rigid retailer routing guides. Technical Considerations for Holiday Fulfillment Packaging To optimize fulfillment packaging during peak season, businesses should evaluate technical performance across multiple areas: Packout efficiency: Design kits and displays with fulfillment-friendly construction (e.g., quick-fold cartons, drop-in inserts, common dimensions) Structural compatibility: Ensure inner packs, cartons, and trays can be packed quickly and securely without secondary rework Barcode and label clarity: Use pre-applied or inline printed labels for traceability, GTIN compliance, and retailer scan accuracy Shipping durability: Account for stacking, vibration, and mixed-freight environments to avoid rework due to damage in transit Vendor-managed inventory (VMI) compatibility: If operating under VMI or JIT models, ensure real-time fulfillment visibility and flexibility The more technical precision built into the packaging, the less risk of costly repackaging, returns, or retail chargebacks during peak execution. The Value of Full-Service Fulfillment Partners Choosing a fulfillment partner who understands packaging, logistics, and compliance is essential. Brown Packaging offers integrated services that support holiday programs from structural design to floor-ready delivery, including: Custom corrugated and display builds Kitting and assembly Retail-ready palletization Labeling and barcoding Inventory staging and JIT release Retailer routing and compliance By coordinating packaging execution with fulfillment from the start, brands can reduce lead times, avoid redundancies, and streamline promotional success. Final Takeaway Peak-season success isn’t about last-minute volume—it’s about early-stage precision. For any brand planning kitting, co-packing, or holiday display builds, the time to secure capacity, align specifications, and test packaging formats is now. By partnering with a fulfillment expert who understands the entire packaging lifecycle, you position your business to deliver seamlessly under pressure—while your competitors scramble to catch up. Need holiday fulfillment support? Brown Packaging provides technical design, fulfillment coordination, and logistics solutions that scale. Let’s plan early and deliver with confidence. (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