Guide / Stage guides / Chapter 9.3
When to switch from stock to custom.
There's no single right moment to move to custom packaging, but there are clear signs. Here's how to tell when custom will save you time and money, how to reduce the risk of switching, and when plain stock is still the better choice.
The short answer
It's usually time to consider custom packaging when you're reordering the same packaging regularly, hand-branding a lot of boxes, no stock size fits well, or the packaging has become part of the product. Plain stock can stay the right choice at any volume, so compare real quotes. If you switch, start with the size you use most. Digital printing starts from 25 units, so you can see a printed box before committing to a larger screen, flexo or offset run from 250 units, although a larger run may use a different print method or board, so check the proof and finish again.
Six signs you're ready
1. You reorder the same packaging every month
Steady, predictable orders are the point where custom packaging makes sense. You know what you need and how many.
2. You're spending time hand-branding
Applying stickers, stamping boxes and folding inserts by hand on hundreds of orders adds up. A printed box does it once, at the factory.
3. No stock size fits well
If you're adding lots of filler or paying for a bigger postage size, a custom-sized box can pay for itself in filler, damage and postage.
4. Customers are sharing their unboxing
When packaging becomes part of why people buy, recommend and post about you, it's worth investing in.
5. You're selling in retail or as gifts
Products on shelves or bought as gifts are judged by their packaging. A printed product box or gift box does work a plain one can't.
6. Your range has settled
Once your best-sellers and sizes are stable, there's less risk of being left with boxes you can't use.
Stock or custom? A quick check
Tick the statements that are true for you. The more ticks, the stronger the case for custom.
| Statement | Points to |
|---|---|
| I order the same box every month | Custom |
| I apply stickers or stamps to most boxes | Custom |
| My product moves around in the closest stock size | Custom size |
| I'm still testing products and sizes | Stay with stock for now |
| I order fewer than a few dozen boxes at a time | Stock, or a small digital run |
| My packaging is part of the gift or retail experience | Custom |
How to reduce the risk of switching
- Start with one box. Print the size you use most and keep the others plain.
- Test with a small run. A digitally printed run from 25 units shows you the fit and how customers respond. It won't show exactly how a later screen, flexo or offset version will look, so check that proof separately.
- Order a sample. Check the size with a plain sample, and ask whether a custom printed sample is available for your product (usually $50–$200, reimbursed when you order).
- Plan the lead time. Order before your current packaging runs out. Digital printing takes 5–10 business days, and screen, flexo and offset printing take 10–15 business days, longer in peak periods.
What it means for you
The same question, answered for where your business is today.
Choose your stage at the top of the page to open the advice for you.
Start-up · under 100 units
If you've just started, stock packaging and branded extras are usually the right choice for now. Revisit the question when you're reordering regularly.
Keep a note of how many boxes you use each month. It's the number you'll need for a quote.
Growing · 100 to 2,499 units
This is the stage many businesses consider the switch, though plain stock can still be right. Start with your most-used box, compare a stock option with a custom quote, and keep the rest of your range on stock packaging for now.
Try this: calculate your current cost per order, including stickers and packing time, and compare it with a custom quote.
Enterprise · 2,500 units and more
At this volume, most packaging is usually custom. Use stock packaging for new products, trials and overflow, and specify everything else.
Review your range each year for sizes that could be combined.
Common mistakes
- 1Switching everything at once. Start with the box you use most and add others as you go.
- 2Going custom before your range settles. You could be left with boxes for products you've stopped selling.
- 3Ignoring the hidden costs of stock. Stickers, filler and packing time are real costs. Include them when you compare.
- 4Leaving the switch too late. Order custom packaging before your current stock runs out.
Switching to custom questions
When should a small business get custom packaging?
Is custom packaging expensive?
Should I switch all my packaging at once?
Can I test custom packaging first?
How long does it take to switch?
From our customers
Growing Calm CollectiveProfessionally printed calico drawstring bags create a warm first impression that reflects the brand's values.
Read their story →Keep reading
Your first custom packaging
Think you're ready for custom?
Tell us what you use now and how many each month. Our Melbourne team will tell you honestly whether custom makes sense yet, usually within 1 business day.