The Ultimate Guide to Custom Printing on Cardboard Boxes

In today’s market, packaging is more than just a protective shell—it’s your silent salesman. And if you're still shipping products in plain brown boxes, you're missing a golden opportunity to leave a lasting impression. That’s where custom printing on cardboard boxes comes in.

Whether you’re running an e-commerce brand, a boutique product line, or a subscription-based business, printed packaging turns your box into a branding tool. It creates recognition, tells your story, and gives your customers a reason to remember—and recommend—you.

In this ultimate guide, we’ll walk you through everything you need to know about custom printed cardboard boxes—including printing methods, design tips, benefits, and how Packaging Forest LLC, the #1 packaging company in the USA, can help you bring your vision to life.

Why Custom Printing Matters More Than Ever

The average consumer sees hundreds of brand messages per day, and packaging is often the only tangible interaction they have with your brand. Custom printing helps your cardboard boxes stand out—visually and emotionally.

Here’s what custom-printed packaging can do:

• Boost brand recognition instantly

• Enhance the unboxing experience

• Create a premium perception

• Make products more giftable or shareable

• Reinforce trust and legitimacy

• Provide information like instructions, ingredients, or social handles

At Packaging Forest LLC, we’ve helped thousands of brands—from startups to household names—turn plain boxes into powerful marketing assets.

Types of Printing for Cardboard Boxes

Not all printing methods are created equal. Each comes with its strengths depending on your box type, order volume, design complexity, and budget.

1. Flexographic Printing

This is the most common method for printing on corrugated cardboard. Think of it as a high-speed stamp with custom rubber plates.

Best for:

• High-volume runs

• Simple designs (1-3 colors)

• Cost efficiency

Pros: Fast, affordable, durable
Cons: Not great for complex graphics or gradients

2. Digital Printing

Digital printing works like an inkjet printer—printing directly onto the box surface without setup plates.

Best for:

• Small to medium runs

• Full-color or photographic designs

• Prototyping or seasonal packaging

Pros: No setup fees, quick turnaround, high detail
Cons: Higher cost per unit for large runs

3. Litho-Laminated Printing

In this method, a high-resolution design is printed on paper, then laminated onto the box.

Best for:

• Retail packaging

• Premium product boxes

• High-end presentation

Pros: Sharp detail, vibrant colors, luxurious feel
Cons: Longer lead times, higher cost

Choosing the Right Box Style

Before you start printing, you need to select the right box structure. Each type offers a different surface area, shape, and folding mechanism—all of which impact design placement.

Common box styles include:

• Regular Slotted Container (RSC) – Standard shipping box

• Mailer Boxes – Perfect for subscriptions or retail

• Tuck Top Boxes – Great for cosmetics or personal care items

• Two-Piece Boxes – Elegant unboxing, ideal for luxury goods

• Unique Shapes – For maximum shelf impact and creativity

For example, our Moon Shaped Packaging Boxes have become a favorite among boutique brands looking to wow customers with non-traditional designs. These are perfect for themed launches, holiday gifts, or unique product displays.

Design Elements to Include on Your Box

When it comes to custom printing, every inch counts. Your design should be intentional, attractive, and aligned with your brand message.

Here are essential elements to consider:

✔ Your Logo

Make sure it's high-res and in a vector format for sharp printing.

✔ Brand Colors

Stick to your primary color palette for consistency across all touchpoints.

✔ Fonts and Typography

Use clear, legible fonts. Keep it minimal to avoid overwhelming the box.

✔ Taglines or Messaging

Use key phrases, slogans, or emotional hooks that align with your product.

✔ Product Info

Ingredients, usage instructions, or social proof (like QR codes or hashtags).

✔ Eco-friendly Messages

If your packaging is recyclable or biodegradable, print that on the box—it matters to your customers.

Benefits of Custom Printing on Cardboard Boxes

Still wondering if it’s worth the investment? Here's why thousands of small and large businesses are switching to printed packaging:

1. Instant Brand Recall

Customers are 70% more likely to remember a brand when it has distinct packaging. A printed box does just that.

2. Better Unboxing Experience

Unboxing is part of your marketing. Make it fun, beautiful, and shareable on social media.

3. Higher Perceived Value

Custom packaging makes your product feel premium—even if it’s not a high-ticket item.

4. Increased Repeat Purchases

Great first impressions lead to stronger customer loyalty and reorders.

5. Eco-Friendly Options

Printed boxes can be made with soy-based inks and recyclable materials—keeping your packaging green and guilt-free.

Printing Best Practices

To get the best results, follow these pro tips:

• Use CMYK color mode for print accuracy

• Submit vector files (.ai, .eps, or .pdf) for logos and graphics

• Avoid over-designing—white space is your friend

• Mock up your box digitally before printing large runs

• Consider interior printing for a hidden surprise or message

At Packaging Forest LLC, we offer free design consultation with every custom order to help you avoid costly mistakes and get the most impact from your print layout.

How Custom Printing Works with Packaging Forest LLC

We make it easy for brands of all sizes to get started with custom-printed boxes. Here’s how the process works:

Step 1: Choose Your Box

Select the shape, size, and material that fits your product. From traditional mailers to custom cuts like Moon Shaped Packaging Boxes,  we’ve got options for every industry.

Step 2: Submit Your Artwork

Upload your logo, brand assets, and any design ideas. Our team will help refine and prepare your files for print.

Step 3: Approve Your Mockup

We’ll send you a digital or physical proof so you know exactly what your box will look like before it goes to production.

Step 4: Print & Ship

Once approved, we’ll start production and deliver your boxes directly to your door—fast, safe, and on brand.

Industries That Benefit Most from Printed Boxes

While every business can benefit from custom-printed packaging, here are a few sectors where it really shines:

• E-commerce and DTC Brands

• Beauty and Skincare

• Food & Beverage

• Health and Wellness

• Gifting and Subscription Boxes

• Luxury and Boutique Retail

No matter your niche, great packaging leaves a lasting impression—and helps you grow organically.

Final Thoughts

If your brand is still sending out plain boxes, you’re not just missing an opportunity—you’re leaving money and attention on the table.

Custom printing on cardboard boxes is one of the highest-ROI moves you can make in your business. It builds trust, tells your story, and sets you apart in a saturated market.

Whether you're going bold and bright or minimal and refined, Packaging Forest LLC has the tools, experience, and creativity to turn your packaging into a powerful part of your customer journey.

Start with something simple, or go all-in with one-of-a-kind creations like our Moon Shaped Packaging Boxes. Whatever your vision, we’re here to print it into reality.