The Ultimate Packaging Guide
Everything a business needs to know about packaging.
Box styles, board grades, printing, artwork, costs and shipping, written by the team behind Australia's largest online packaging range. Pick your stage and we'll show you what matters first.
Start here
Where is your business right now?
The right packaging depends on how many you order of each design. Quantities are units per order or per design. Each path covers the topics that matter at your volume, in the order you need them.
Part 1 · 8 chapters
Packaging basics
Types of packaging, measuring, box sizing and cubic weight.
What is the difference between primary, secondary and tertiary packaging?
How do I measure a product to find the right box size?
Are box sizes internal or external, and why does it matter?
How much space should I leave around a product in a box?
What is cubic weight and how does box size change shipping cost?
What should I tell a supplier to get the right packaging quoted?
What do packaging terms like flute, dieline and GSM mean?
Should I buy stock packaging or custom packaging?
Part 2 · 23 chapters
Box & packaging styles
Every common box and bag style, what it does and when to use it.
What is a regular slotted carton and when should I use one?
What is a die-cut mailer box and why are they popular for e-commerce?
Are self-sealing boxes worth it?
What is the difference between reverse tuck and straight tuck end boxes?
What is a snap lock bottom box and when do I need one?
What is a crash lock box and how is it different from snap lock?
How do hanger boxes work for peg displays?
When should I use a two-piece lid and base box?
What are rigid boxes and why do premium brands use them?
Are magnetic boxes worth the cost?
How do collapsible rigid boxes save freight and storage?
What are pillow boxes good for?
How do sleeves and drawer boxes work?
When should packaging have a window?
How do multi-crease boxes reduce empty space?
What packaging protects books in the post?
How do I post posters and prints safely?
What is the safest way to package and ship bottles?
When are carry packs the right choice?
How do counter display boxes help retail sales?
How do pick bins organise a warehouse?
Which bag suits retail, gifting or takeaway?
Satchel, padded mailer or paper mailer: which should I use?
Part 3 · 10 chapters
Materials & board grades
Flutes, board strength, kraft vs white, paperboard and finishes.
What are E, B, C and BC flutes and which do I need?
How is cardboard strength measured (ECT, burst)?
When do I need double wall boxes?
Should my boxes be kraft brown or white?
What GSM paperboard should I use for product boxes?
What are rigid boxes made from?
Is recycled cardboard as strong as virgin board?
Which finish suits my packaging?
Are paper mailers better than plastic satchels?
What should I check before packaging food?
Part 4 · 12 chapters
Printing
Digital, screen, flexo and offset, plus foil, embossing and colour.
Which printing method is right for my packaging?
When is digital printing the best choice?
How does screen printing work on boxes and bags?
What is flexographic printing and why is it used for cartons?
When is offset printing worth it?
What does foil stamping add and what does it cost?
What is the difference between embossing and debossing?
What is spot UV and when does it work?
Can you print inside a paperboard box, and when is it worth it?
Why doesn't my printed colour match my screen?
How do colours print on brown kraft?
What is the cheapest way to brand packaging?
Part 5 · 8 chapters
Artwork & design
Dielines, bleed, file setup, proofs and the unboxing.
What is a dieline and how do I use one?
How much bleed does packaging artwork need?
What file format should packaging artwork be?
What should I check on a packaging proof?
Why does my logo look blurry when printed?
How should design change between digital and flexo runs?
How do I create a memorable unboxing?
What must be printed on product packaging in Australia?
Part 6 · 9 chapters
Ordering & production
Minimum orders, lead times, samples, cost and planning.
Why do packaging suppliers have minimum orders?
How long does custom packaging take?
Should I order a sample before buying packaging?
Why does custom packaging cost what it does?
How does ordering more lower the price per box?
What do I need to get a packaging quote?
How much packaging stock should I hold?
When should I order packaging for Christmas?
How do I write a packaging specification?
Part 7 · 9 chapters
Shipping & protection
Void fill, fragile items, courier sizing and freight.
Paper, honeycomb, bubble wrap or shredded paper: which void fill should I use?
How do I ship glass and ceramics without breakage?
Should I ship in a satchel or a box?
How do packaging rules differ between couriers and Australia Post?
How can I test packaging before I ship?
How do I stop products arriving damaged?
How should cartons be packed on a pallet?
Which tape seals boxes properly?
How can packaging lower my shipping costs?
Part 8 · 8 chapters
Sustainability & rules
Recycling, compostables, FSC, plastic bans and honest claims.
What is the difference between recyclable, compostable and biodegradable?
What is the ARL and do I need it?
What does FSC certified packaging mean?
Which plastic packaging is banned in my state?
What are Australia's packaging targets?
What do Australian exporters need to know about EU packaging rules?
How can I reduce packaging safely?
How do I make environmental claims without greenwashing?
Part 9 · 5 chapters
Stage guides
Advice written for start-ups, growing businesses and enterprise.
How can a new business get great packaging on a small budget?
What should I know before my first custom packaging order?
When is it worth moving to custom printed packaging?
How do I keep packaging simple across many products?
How do larger businesses keep packaging supply reliable?
Rather talk it through?
Tell us what you're packing and how many you need. Our Melbourne packaging team replies within 1 business day.