The enterprise path · 2,500 units and more
Packaging at scale, specified properly.
At volume, every millimetre, gram and day of lead time matters. These chapters cover specifying board and print, planning supply around lead times and peak seasons, and cutting freight and damage across thousands of shipments.
The short answer
At 2,500 units and more per order or per design, write a packaging specification and agree an approved reference sample and tolerances so every order is consistent, choose print methods built for longer runs (flexo for cartons, offset for paperboard), and plan orders around confirmed lead times. Right-sizing and board choice now have the biggest effect on freight and damage costs.
Where to focus
- Specify everything. Board, flute, dimensions, print method and colours in one document your team and supplier both use.
- Plan around lead times. Screen, flexo and offset printing usually take 10–15 business days from artwork approval, and rigid boxes, magnetic boxes and foil take longer. Lead times are longer in peak periods, so check our current lead times and build them into your reorder points.
- Test at scale. Small changes to box size or board multiply across every shipment, so test with real loads before you commit.
Your chapters, in order
Work through these in order, or jump to what you need. Your progress is saved on this device.
- 01How strong is my box? Flutes, walls and load5 min
How is cardboard strength measured (ECT, burst)?
- 02Single wall vs double wall5 min
When do I need double wall boxes?
- 03Flexo printing for cartons4 min
What is flexographic printing and why is it used for cartons?
- 04Offset printing for retail packaging4 min
When is offset printing worth it?
- 05CMYK, Pantone and colour matching5 min
Why doesn't my printed colour match my screen?
- 06Designing for small vs large print runs5 min
How should design change between digital and flexo runs?
- 07Cost per unit vs order size5 min
How does ordering more lower the price per box?
- 08How to get an accurate packaging quote5 min
What do I need to get a packaging quote?
- 09Packaging specifications for consistent supply5 min
How do I write a packaging specification?
- 10Reducing damage and returns5 min
How do I stop products arriving damaged?
- 11Palletising and freight5 min
How should cartons be packed on a pallet?
- 12Planning packaging supply at scale5 min
How do larger businesses keep packaging supply reliable?
- 13How to write a packaging brief7 min
What should I tell a supplier to get the right packaging quoted?
- 14Exporting to the EU: packaging rules (PPWR)6 min
What do Australian exporters need to know about EU packaging rules?
What most businesses at this stage order
Planning a large run?
Send us your specifications, quantities and timing. Our Melbourne team will come back with options, usually within 1 business day.