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.
Retailers place strict requirements on packaging to ensure products move efficiently through distribution centers, arrive safely, and look consistent on shelves. Non-compliance can lead to costly chargebacks, rejected shipments, and damaged retailer relationships. Buyers must design packaging that meets performance, labeling, and sustainability standards to avoid disruptions. Why Retail Compliance Matters Financial impact: Chargebacks and penalties cut into margins. Operational delays: Non-compliant packaging can hold up entire shipments. Retailer trust: Consistent compliance builds long-term partnerships. Shelf presence: Packaging that aligns with planograms avoids disruptions at store level. Key Compliance Requirements Structural standards: Packaging must meet durability and palletization guidelines. Labeling accuracy: GS1-compliant barcodes and proper product details. Sustainability mandates: FSC certification or recyclability requirements from major retailers. Testing protocols: ISTA or ASTM performance tests to validate protection. Common Causes of Non-Compliance Incorrect pallet sizes or overhang. Weak corrugated grades that collapse under stacking. Missing or unreadable barcodes. Excess packaging waste conflicting with retailer eco goals. How to Improve Retail Compliance Standardize box sizes to match retailer pallet and shelf guidelines. Validate packaging with ISTA or ASTM testing before rollout. Collaborate with suppliers who understand retailer-specific requirements. Audit packaging regularly to stay aligned with updated standards. Packaging Solutions with Brown Packaging Brown Packaging partners with companies to design packaging that meets retailer requirements. From GS1 labeling to FSC-certified materials and ISTA-tested corrugated, we help buyers reduce chargebacks and protect retail relationships. Contact us to improve your retail compliance program. References GS1. (2024). Global Standards for Packaging and Labeling. Retrieved from https://www.gs1.orgInternational Safe Transit Association (ISTA). (2023). ISTA Testing Procedures for Transport Packaging. Retrieved from https://ista.orgForest Stewardship Council (FSC). (2023). FSC Packaging Certification Guidelines. Retrieved from https://fsc.org (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. Retail Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
RSC boxes dominate shipping because they combine strength with efficiency. But beyond protection, their dimensions and stacking performance directly influence freight cost, pallet utilization, and warehouse efficiency. Choosing the right RSC design can reduce supply chain costs by double digits. Pallet Utilization Box Size and FitAn RSC that doesn’t optimize pallet footprint wastes space. Even a 1–2 inch mismatch can reduce units per pallet by 5–10%. Standard Pallet SizesIn North America, most pallets are 48” x 40”. Designing RSC dimensions to fit evenly across this footprint maximizes stacking stability. Load StabilityUniform RSC dimensions improve compression strength across the load, reducing toppling and damage in transit. Dimensional Weight (DIM) Charges Carrier Pricing ModelsCarriers like UPS and FedEx charge based on dimensional weight, not just actual weight. Oversized RSC boxes can inflate costs significantly. Right-SizingSelecting an RSC that closely matches product volume reduces cube size, cutting freight charges. Impact on E-CommerceFor direct-to-consumer shipments, oversize RSC boxes can double shipping cost while raising material expense. Stacking and Compression Box Compression Test (BCT)Determines how much weight an RSC can withstand in a stacked load. Real-World FactorMoisture and long-term storage reduce compression strength. Oversizing boxes to “play it safe” only increases freight cost. Instead, balance board grade with actual load needs. Warehouse Efficiency Knock-Down StorageRSC boxes ship and store flat, reducing warehouse footprint compared to assembled specialty mailers. AutomationConsistent RSC dimensions reduce jams in case erectors and palletizers, improving throughput. Buyer Takeaway Use RSC dimensions that align with pallet footprints to maximize utilization. Avoid oversized boxes — dimensional weight charges add hidden costs. Match board grade and box size to actual load requirements instead of over-specifying. Optimized RSC design isn’t just packaging — it’s a supply chain cost-control tool. References Fibre Box Association. (2023). Palletization and Shipping Standards. https://www.fibrebox.org International Safe Transit Association (ISTA). (2023). Distribution Testing Protocols. https://ista.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 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 Regular Slotted Container (RSC) Facebook Twitter LinkedIn Pinterest Relevant Posts
The Regular Slotted Container (RSC) is the most widely used corrugated box style in the world. Its simplicity, manufacturing efficiency, and versatility make it the default choice across industries ranging from industrial parts to e-commerce fulfillment. Understanding what makes RSC boxes so effective helps buyers decide when standardization is the best approach — and when alternatives may be worth considering. What Defines an RSC Box An RSC is manufactured from a single sheet of corrugated board with flaps of equal length that meet at the center when folded. The design minimizes board waste, requires only a single die-cut or slotting process, and can be assembled with tape, glue, or staples. Its dimensions can be adjusted easily to accommodate nearly any product size. Why RSC Remains the Standard Manufacturing Efficiency RSCs use minimal board compared to other box styles. They can be produced on high-speed corrugators and folder-gluers without complex tooling. Standardized sizes reduce lead times and lower setup costs. Structural Strength The design maximizes stacking strength with flaps that reinforce the edges of the container. Compatible with a wide range of flute profiles and board grades, from single-wall E-flute to triple-wall heavy-duty. Versatility Works for products ranging from lightweight consumer goods to heavy industrial components. Compatible with automation in packing, sealing, and palletization systems. Easily branded with flexographic or digital print for retail and e-commerce applications. Cost Effectiveness Board utilization is highly efficient, reducing waste. Standardized production reduces cost per unit at scale. Assembly and sealing are simple, requiring minimal labor and materials. Limitations of the RSC While RSC is unmatched for general-purpose shipping, it’s not always the best option: Requires tape, glue, or staples, which adds materials and labor. Lacks the premium presentation of die-cut mailers for e-commerce. For unusually heavy or fragile products, other styles (like Full Overlap or RETT) may provide better performance. Buyer Takeaway RSC boxes dominate corrugated packaging for one reason: they offer the best balance of strength, efficiency, and cost. If your priorities are bulk shipping, pallet strength, and scalability, RSC is almost always the right choice. But for premium presentation, automation-friendly features, or specialty protection, it’s worth exploring alternative styles. References Fibre Box Association. (2023). Corrugated Box Styles and Design Guide. https://www.fibrebox.org Association of Independent Corrugated Converters (AICC). (2024). Corrugated Packaging Fundamentals. 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 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 Regular Slotted Containers Facebook Twitter LinkedIn Pinterest Relevant Posts
RSC boxes are known for their efficiency and versatility, but their performance ultimately comes down to strength. Buyers often see numbers like ECT, BCT, and burst strength on specifications — but which tests matter most, and what do they actually measure? Choosing the right RSC depends on understanding how these tests translate to real-world shipping conditions. Edge Crush Test (ECT) What It Measures Resistance of corrugated board to edgewise compressive forces. Expressed in pounds per inch (e.g., 32 ECT). Why It Matters Directly tied to stacking strength and pallet performance. The most common metric used in North America for corrugated box strength. Limitations Only measures board strength, not the full box. Doesn’t account for humidity, handling abuse, or long-term compression. Box Compression Test (BCT) What It Measures Maximum load a finished box can withstand before collapsing. Accounts for box size, design, and board strength. Why It Matters Most accurate predictor of how an RSC will perform in stacking and pallet loads. Useful for optimizing board grades to reduce cost without risking damage. Limitations Requires lab testing of actual boxes. Not always practical for small-volume or custom runs. Burst Strength (Mullen Test) What It Measures Pressure required to rupture corrugated board by puncture. Historically the go-to test before ECT became standard. Why It Matters Still relevant for industries where puncture or tearing is a higher risk than compression (e.g., heavy parts, bulk industrial goods). Limitations Doesn’t reflect stacking strength. Often replaced by ECT in modern logistics. Translating Tests to Real-World Performance High-Volume E-Commerce: ECT rating is usually the key metric, especially for stacking in warehouses. Heavy Industrial Products: Burst strength may be more relevant if products are sharp or heavy. Palletized Loads: BCT is the best indicator, as it measures box and board performance together. Moisture & Humidity: None of the above tests fully account for water absorption — additional treatments or coatings may be necessary. Buyer Takeaway Look for ECT when evaluating basic strength requirements. Prioritize BCT if your shipments are palletized or stacked in warehouses. Consider burst strength if your products are heavy, sharp, or prone to puncture risks. Remember: lab tests are only part of the story — real-world conditions like humidity, handling, and long-term storage will also affect performance. References Fibre Box Association. (2023). Box Performance Standards. https://www.fibrebox.org TAPPI. (2024). Testing Methods for Corrugated Packaging. https://www.tappi.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 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
In packaging, foam isn’t just about initial protection — it’s about maintaining performance over the entire shipping or storage cycle. Compression set and recovery characteristics determine whether foam continues to provide shock absorption after being loaded, stacked, or stored for long periods. What Is Compression Set? Definition: The permanent deformation a foam retains after being compressed for a defined time and temperature. Why It Matters: A foam that takes a high compression set loses thickness and cushioning capability, leaving products more vulnerable to impact damage. Typical Measurement: Reported as a percentage loss of original thickness after the load is removed. Recovery Rate and Load Retention Recovery Rate: How quickly foam returns to its original dimensions after load removal. Load Retention: The ability to maintain performance over repeated load cycles — crucial for returnable and reusable packaging. High recovery and load retention mean the foam can be used multiple times without replacement. Factors Affecting Compression Set Foam Chemistry: Crosslinked PE typically offers lower compression set than non-crosslinked. PU foams may be softer but often exhibit higher permanent deformation under load. Density: Higher-density foams resist deformation better but may be heavier and costlier. Environmental Conditions: Heat and humidity accelerate compression set in most foam materials. Testing and Standards ASTM D3574 Test D: Measures compression set under specified load and temperature. ASTM D3574 Test B1/B2: Evaluates indentation force deflection for load-bearing properties. ASTM D1055: For rubber-like cellular materials, often applicable to certain elastomeric foams. Design Strategies Load Distribution: Use ribbed or contoured inserts to spread weight across more surface area. Material Blends: Combining foams with different recovery characteristics can balance softness and durability. Replace on Schedule: In closed-loop systems, track cycle counts and replace foam before performance degradation risks product safety. References ASTM International. (2021). ASTM D3574-21: Standard test methods for flexible cellular materials—Slab, bonded, and molded urethane foams. ASTM International. https://www.astm.org/d3574-21.htmlASTM International. (2014). ASTM D1055-14: Standard specification for rubber cellular sheeting—Closed cell. ASTM International. https://www.astm.org/d1055-14.html (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. Custom Foam Facebook Twitter LinkedIn Pinterest Relevant Posts