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.
When working with thick foam materials in the packaging industry, it’s important to be aware of the natural outcomes of the die-cutting process—one of the most common being concavity. This phenomenon occurs when thick foam is cut into specific shapes, resulting in the sides of the die-cut parts appearing concave rather than perfectly straight. Understanding why this happens and how it impacts the final product is essential for anyone involved in packaging design and production. What is Concavity in Die-Cut Foam? Concavity refers to the inward curvature of the sides of a thick foam part after it has been die-cut. During the cutting process, the knife penetrates the foam, applying pressure unevenly across the material’s thickness. The top layer of foam experiences minimal compression as the knife begins its cut, while the middle and bottom layers undergo greater compression as the knife moves downward. This difference in compression causes the sides of the foam part to curve inward, creating a concave effect. Why Does Concavity Occur? The occurrence of concavity is directly related to the mechanics of the die-cutting process, particularly when dealing with thicker foam materials. As the die-cutting knife enters the foam, the pressure applied is not uniform across the entire thickness of the material. The initial entry of the knife into the top layer results in less compression, while the subsequent layers experience increasing levels of compression as the knife cuts deeper. This uneven pressure distribution is what leads to the concave sides. It’s crucial to recognize that concavity is not a flaw but rather a natural characteristic of die-cutting thick foam. Understanding this aspect of the process allows for better planning and consideration when designing and producing packaging solutions that utilize thick foam materials. Considerations for Packaging Design When designing packaging that involves thick foam die-cut parts, it’s important to account for the potential concavity of the sides. This feature should be factored into the overall design to ensure that it does not interfere with the functionality or appearance of the packaging. In most cases, concavity does not impact the performance of the foam part, but it’s essential to be aware of its presence during the design phase. For applications where the appearance or specific fit of the foam is critical, additional measures may need to be taken to address or minimize concavity. However, for many packaging solutions, the concave sides of die-cut foam parts will not affect their ability to provide cushioning, protection, or support. Conclusion Concavity in thick foam die-cut parts is a natural and expected outcome of the die-cutting process. Understanding this phenomenon is key to making informed decisions during the packaging design and production process. By accounting for concavity in your designs and recognizing its impact—or lack thereof—on the final product, you can ensure that your packaging solutions are both effective and reliable. As with any aspect of packaging production, being informed and prepared is essential to achieving the best possible results. (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. Foam Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Mailing tubes have long been a popular choice for shipping and storing various items, from posters and blueprints to documents and delicate artworks. While they serve their purpose effectively, there are alternative packaging solutions that can offer unique advantages and benefits. In this comprehensive guide, we will explore alternative packaging options to mailing tubes, considering various materials, designs, and their suitability for different types of contents. The Limitations of Mailing Tubes Before delving into alternative packaging options, it’s essential to understand the limitations of mailing tubes: Limited Shape Compatibility: Mailing tubes are primarily designed for long, cylindrical items. They may not be suitable for irregularly shaped or flat objects. Lack of Padding: Mailing tubes typically provide minimal protection against impact and bending. Fragile or sensitive items may require additional padding. Storage Challenges: Mailing tubes can be difficult to store efficiently, especially when dealing with a large quantity of varying tube sizes. Now, let’s explore alternative packaging options: Corrugated Boxes Corrugated boxes come in various sizes and shapes, making them versatile for different types of items. They offer more robust protection than mailing tubes and can be customized with dividers, foam inserts, or partitions to secure fragile objects. Corrugated boxes are also easier to stack and store. Bubble Mailers Bubble mailers, or padded envelopes, are lightweight and provide cushioning for small to medium-sized items. They are an excellent choice for documents, books, clothing, and small electronics. Bubble mailers come in different sizes and offer a cost-effective alternative to mailing tubes. Flat Mailers Flat mailers are perfect for shipping flat or thin items such as photographs, artwork, or documents. They are designed to prevent bending or damage during transit. Flat mailers often have rigid or reinforced designs for added protection. Expandable Mailers Expandable mailers are ideal for items that may vary in thickness. They feature a gusseted design that allows the mailer to expand to accommodate thicker contents. This versatility makes them suitable for various products, including books and catalogs. Rigid Mailers Rigid mailers, also known as chipboard mailers or stay flat mailers, provide sturdy protection for delicate items like photographs and prints. They are constructed from rigid cardboard or paperboard and come in various sizes. Telescopic Boxes Telescopic boxes consist of two parts that slide into each other, providing adjustable length. They are a great alternative for items that require a secure and expandable packaging solution, such as posters or rolled documents. Poly Mailers Poly mailers are lightweight and water-resistant, making them suitable for shipping clothing, accessories, and non-fragile items. They come in various sizes and can be customized with branding or labeling. Custom Packaging Solutions Depending on your specific needs, you can explore custom packaging solutions tailored to your product requirements. Custom packaging allows you to design packaging that perfectly fits your items, ensuring maximum protection and brand presentation. Choosing the Right Alternative Selecting the right alternative packaging to mailing tubes depends on the nature of your products, shipping requirements, and budget considerations. Carefully assess the size, shape, and fragility of your items, as well as your branding and sustainability goals. By exploring these alternative packaging options, you can find a solution that not only protects your contents during transit but also aligns with your overall packaging strategy. If you are interested in alternative packaging to mailing tubes, 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. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
In the world of packaging, the visual appeal of your product plays a significant role in catching the customer’s eye and leaving a lasting impression. Roll End Tuck Top (RETT) boxes, known for their durability and versatility, provide an excellent canvas to enhance the presentation of your products. In this detailed blog, we will explore 12 effective strategies and tips on how to maximize the presentation of your RETT boxes to create a memorable unboxing experience for your customers. Creative Branding Custom Printing Consistency Across Products Window Inserts Embossing and Debossing Custom Die-Cut Shapes Matte or Glossy Finish Branding Inside the Box Personalized Touch Seasonal or Limited-Edition Packaging Professional Photography Creative Branding Utilize the ample space on RETT boxes for creative branding. Include your company logo, eye-catching graphics, and product information. A well-designed box instantly communicates your brand identity and sets the tone for the unboxing experience. Custom Printing Invest in high-quality custom printing to ensure that your RETT boxes are visually striking. Vibrant colors and sharp imagery can make your packaging stand out and pique the customer’s interest. Consistency Across Products Maintain consistency in your packaging design across different products or product lines. A cohesive look reinforces your brand and makes your products easily recognizable. Window Inserts Consider adding window inserts to your RETT boxes. These transparent openings allow customers to preview the product inside, adding intrigue and enticing them to open the box. Embossing and Debossing Embossing and debossing techniques can add texture and depth to your packaging. Raised or recessed patterns or designs create a tactile experience that elevates the perceived value of your products. Custom Die-Cut Shapes Opt for custom die-cut shapes for your RETT boxes to make them unique and attention-grabbing. Unconventional shapes can make your packaging more memorable. Matte or Glossy Finish Choose between matte and glossy finishes to complement your brand’s aesthetics. Matte finishes exude sophistication, while glossy finishes provide a polished and vibrant look. Branding Inside the Box Don’t neglect the interior of your RETT boxes. Adding branding elements, messages, or design accents inside the box enhances the overall unboxing experience and surprises customers. Personalized Touch Consider adding a personalized touch, such as a handwritten thank-you note or a small promotional item, to show appreciation to your customers and leave a positive impression. Seasonal or Limited-Edition Packaging For special occasions or limited-edition products, create seasonal or unique packaging designs. These limited runs can generate excitement and encourage purchases. Professional Photography When showcasing your products online or in marketing materials, use professional photography to highlight the packaging’s visual appeal and its role in enhancing the product presentation. Conclusion Maximizing the presentation of your RETT boxes involves careful consideration of design, materials, and branding. These packaging strategies can significantly impact the customer’s perception of your products and brand. By investing in creative design, custom printing, and unique features, you can create a memorable unboxing experience that leaves a lasting impression on your customers, ultimately contributing to increased brand loyalty and customer satisfaction. If you are interested in roll end tuck top 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. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Rigid boxes are the gold standard of premium packaging. Whether used for cosmetics, electronics, fashion, or high-end subscription kits, rigid boxes do more than protect your product—they create a lasting brand experience from the moment they’re opened. Here are the 9 most popular luxury features that elevate rigid box packaging and help brands stand out. Magnetic Closures A magnetic flap provides a smooth, satisfying opening experience and a sleek finish. It reinforces quality while offering functional security, commonly seen in beauty kits, tech packaging, and luxury gift sets. ✔ Clean, modern aesthetic ✔ Adds perceived value ✔ Easy for repeated opening and closing Custom Inserts Custom-cut inserts made from foam, chipboard, or thermoform plastic keep products secure, organized, and beautifully presented. They protect during shipping and add structure inside the box. ✔ Product protection with precision ✔ Enhances unboxing experience ✔ Reinforces product value and care Soft-Touch Finishes This premium matte coating adds a velvety, upscale texture to the surface of the box, often used in high-end minimalist packaging. ✔ Sophisticated feel ✔ Pairs well with foil or spot UV ✔ Encourages tactile engagement Embossing & Debossing Embossing raises elements like logos or patterns, while debossing presses them in. Both add texture, contrast, and elegance to your packaging. ✔ Elevates brand identity ✔ Adds depth and dimension ✔ Perfect for logo treatments or special accents Foil Stamping A favorite in luxury packaging, foil stamping applies metallic shine to logos, text, or design elements. Popular foil colors include gold, silver, copper, and rose gold. ✔ Instantly communicates premium quality ✔ Draws attention to key visuals ✔ Common in cosmetics, spirits, and premium retail Ribbon Pulls or Fabric Handles Add a layer of refinement with ribbon pulls or woven handles. They improve function while reinforcing a soft, giftable feel. ✔ Invites interaction ✔ Enhances presentation ✔ Adds softness and charm Hidden Compartments or Dual Layers Add intrigue and functionality with a multi-layer structure or secret compartment inside the box—great for curated sets or sample bundles. ✔ Creates discovery moments ✔ Encourages deeper engagement ✔ Boosts perceived value Full Interior Printing The inside of the box is a powerful branding space. Custom interior printing can feature messaging, design accents, or even surprise graphics. ✔ Extends branding beyond the exterior ✔ Adds polish and surprise ✔ Encourages unboxing shares on social media Unique Structural Designs Innovative formats like drawer boxes, book-style closures, or hinged lids make the box itself part of the product story. ✔ Distinctive and memorable ✔ Supports retail display appeal ✔ Perfect for high-end kits and influencer boxes Final Thoughts Luxury is in the details. These nine features take rigid box packaging from standard to unforgettable—delivering not just a product, but an experience. Whether you use one or combine several, these enhancements can elevate your packaging and strengthen your brand image. Need help building a rigid box that delivers luxury and functionality? We’ll help you bring together the right structure, materials, and finishes to match your product and market 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. Rigid Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts
Understanding One-Piece FOL and Three-Piece Bike Shipping Boxes Choosing the right box style is essential when shipping bicycles—especially for brands, manufacturers, and distributors focused on protection, cost efficiency, and streamlined logistics. Two commonly used formats are the Full Overlap (FOL) one-piece box and the three-piece bike box. Each has distinct structural advantages depending on the bike type, destination, and handling environment. What Is a Full Overlap (FOL) Bike Shipping Box? A Full Overlap (FOL) box is a one-piece corrugated shipping box where the top and bottom flaps fully overlap each other when closed. This design is especially valuable for long or narrow products like bikes. Benefits include: Strong Compression Resistance – The full overlapping flaps provide double-layered protection on the top and bottom panels. Simplified Handling and Assembly – Arrives as a single piece and requires only folding and taping, making it efficient for production lines. Cost-Effective for Standard Shipments – Fewer components and straightforward manufacturing keep material and labor costs low. Ideal for Flat-Pack or Dismantled Bikes – Works well for partially disassembled bikes with adequate internal protection. What Is a Three-Piece Bike Shipping Box? A three-piece box includes a base, a lid, and a center sleeve that wraps vertically around the bike. This structure is often used for premium or specialty bikes that require enhanced protection. Key advantages: Superior Durability and Protection – Multiple corrugated layers absorb impact, stacking pressure, and long-haul wear. Height Flexibility – The sleeve allows the box height to adjust to fit different bike sizes or accessory configurations. Excellent for Fragile or High-Value Bikes – Ideal for electric bikes, luxury models, or international shipments where added security is crucial. Enhanced Brand Presentation – The modular design offers more surface area and structural options for branded unboxing experiences. FOL vs. Three-Piece: Key Differences Feature FOL (One-Piece) Box Three-Piece Box Components Single box with overlapping flaps Base + Lid + Sleeve Protection Level Moderate – suitable for standard use High – layered protection for fragile items Assembly Fast, efficient Requires more steps and alignment Material Usage Less – more cost-efficient More – adds reinforcement and dimensional control Best For Flat-packed bikes, short-distance High-end bikes, eBikes, or global distribution Which Bike Shipping Box Is Right for Your Business? The decision depends on your bike model, packaging workflow, and shipping conditions: Use an FOL box when speed, simplicity, and cost efficiency are priorities—especially for standard bikes with proper internal bracing. Choose a three-piece box when your product demands premium protection, flexible sizing, or is headed to distant or high-risk destinations. Custom Structural Packaging for Bikes Both FOL and three-piece bike boxes can be optimized with: Die-cut inserts or partitions for immobilizing frames and wheels Branded folding cartons for manuals, tools, or accessories Foam, corrugated, or molded trays for secure internal protection Print-ready panels for logos, instructions, or compliance labels Looking for a purpose-built solution? Brown Packaging can help you engineer a custom structure that ensures protection, efficiency, and brand value. (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. Bike Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts