New 18x12x6 die cut mailer sizeWhen you want to make a great impression on your customer but your product is large and bulky, what do you do? You can ship it in an RSC style shipping box which does not require any tooling but is not the “presentation” container you might prefer. You can have someone like us create a custom size cutting die for you but that could cost as much as a thousand dollars which is tough to justify for low to medium volume applications that may also be seasonal.

Or you can use one of our many oversized, available cutting dies that create die cut mailers with an attached lid and are impressive (compared to RSC style shipping boxes) whether they are printed or not. We have a new size available that may satisfy your needs. It is 18-3/4” long X 12” wide X 6-1/16” high. It is a front lock design and features side dust flaps for security and cleanliness. It is ideal for countless applications including the packaging and shipping of:

  • Wearing apparel
  • Bedding and towels
  • Toys and stuffed animals
  • Full size snack portions
  • Prepared food and ingredients

printed version of our 15x10x10 mailer boxMOQ and Custom Printing

This new available size is currently NOT a stock product so the minimum order quantity, printed or unprinted is 1,000 boxes. It can be produced in white board inside or outside or of course, in standard natural Kraft (brown). We can print it inside or outside, but your print plates will be an additional onetime cost.

Other Available Oversized Box Sizes

In addition to this new size, we do have other extra-long, extra wide or extra tall die cut mailers sizes we can make. They include:

  • 24” X 15-1/2” X 5-1/4”
  • 21” X 11” X 11”
  • 15” X 10-1/2” X 10-1/2”
  • 14-1/2” X 9-1/2” X 6-1/4”
  • 13” X 13” X 6”

These boxes are also non-stock, but can be run with the 1,000 MOQ in white or brown, and custom printed.

Please contact us at Salazar Packaging or call us at 815-609-3600 to discuss your specific needs. We also invite you to visit our gallery where you will see what we can do to help you deliver your brand to your customers.

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USA-CanadaNot that long ago, moving business “south of the border” meant moving production and packaging to Mexico. Today it is more likely to be e-commerce or subscription box operations and the border they are crossing is the one between Canada and the USA.

We noticed a sharp increase in the number of Canadian based companies that are considering or have moved their packaging and fulfillment to the USA, and of course, we became interested in what might be driving it. We asked a few of our Canadian friends and customers and received answers we can all learn from.

Variety of inside and ouside custom printsWhere the Customers Are

The USA obviously has a larger overall population with many large geographic consumer markets to offer. Unless the product being shipped is exclusively of interest to Canadians (which is not usually the case), it is likely if not probable that the majority of the subscriptions and customers will be in the USA.

Inbound Shipping Cost Savings

Setting up a fulfillment operation in the USA can save a lot of money in terms of inbound shipping whether the suppliers of products and packaging are in the USA or even in Canada. LTL common carrier shipping is all about “lanes” and the more companies and trucks that go there, the more likely you are to find a competitive situation that produces real and in many cases, substantial savings.

Outbound Shipping Cost Savings

As most subscription box and e-commerce shippers discover, the cost of shipping the product to the customer is usually the single greatest cost and can make the difference between making money or losing it. One of our Canadian friends shared that shipping to some USA customers from Canada can cost as much as three times more. Few margins can support that type of shipping cost differential.

A Larger Supplier and Service Base

The three things any packaging buyer seeks are quality, service and of course price; and the USA will typically offer more potential sources to choose from. More options will usually result in better quality and service, but it will always result in greater savings due to the larger, more compettive market.

An Exchange Rate that Currently Favors the USA

Unlike a few years ago when the USA dollar was weak compared to that of our Canadian neighbors, the current exchange rate has shifted dramatically in favor of the USA. Buying USA products and services with Canadian dollars is not as favorable as it used to be so at least for now, setting up a USA based operation makes a lot of sense and money.

At Salazar Packaging and Globe Guard Products we study and learn from the market and these are the current conditions. Everything is subject to change but for now, setting up in the USA might be beneficial to many Canadian based companies. I think everyone will agree that this is smart business whether you are just starting out or have thousands of subscribers.

If and when that move is made, we hope you will consider us when looking for a great supplier of beautiful e-commerce and subscription boxes. Please contact us at Salazar Packaging or call us at 815-609-3600.

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6.25 x 4.125 x 2 lock front mailer in stockIt always thrills us to identify new sizes our store customers need so we can add them to inventory. Both sizes are now stocked in Kraft (brown) and also available in white with a 1,000 minimum order quantity.

From now through November 30, 2015, these two new sizes will be on sale at

Two New Mailer Box Sizes

6-1/4” X 4-1/8” X 2” – front lock, die cut mailer. We think this is going to be a popular size for everything from jewelry, to E-juice. They are made of very popular B-flute board and are made of a minimum of 60% recycled content. They are also 100% recyclable, repulpable and even compostable. They also feature the Globe Guard logo on the bottom of each box so your customers know you are using one of the greenest shipping options available.

9-1/2” X 6-1/2” X 4-1/2”- front lock, die cut mailer. Given the popularity of our 12-1/4” X 9-1/4” X 4” box and our 10” X 8-1/2” X 4” sizes, we think this is going to be ideal for customers who want a slightly smaller box to reduce shipping costs. It could be a great size for snack samples, socks, and even personal care product, E-commerce and subscription boxes.

New 9.5 x 6.5 x 4.5 box also available cusotm printedAlso Available Custom Printed

Like all of our stock boxes, these two new sizes are available custom printed with your colors and brand in a very low, 1,000 MOQ. You save at least $800 by NOT having to buy a cutting die and only purchasing your print plates for a onetime cost that is usually between $400 and $600 per color.

What Box Size Do YOU Need?

We have grown tremendously in the last eight years by being responsive to our customers. These two new sizes are a direct result of customer feedback, so if there is a size you wish we had available, let us know. If you use it on a regular basis and we believe others will also be able to utilize it, we will consider adding it to inventory.

We are always willing and eager to discuss your specific needs and application. You can contact us at Globe Guard Products or call us at 815-609-3600.

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LABELbox_6982WEBOur stock labels are 100% recycled content and are available in six popular sizes and configurations. They are one of the greenest labels available and complement our Globe Guard eco-friendly boxes beautifully.

Now though the end of October we are pleased to offer them on sale, with a discount no less than 15% plus FREE SHIPPING! was one of the very first web sites offering eco-friendly products and seven years later, we are still going strong. If you have not been there lately, check out some of the new products we’ve added including our Reusable Box Sealer™, our variety of unprinted e-commerce and subscription boxes.

Please contact us at Globe Guard Products or call us at 815-609-3600 if you have questions on any of our stock (unprinted) or custom size, custom printed packaging.

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Why Use Globe Guard® Stock Mailer Boxes?

Globe Guard Stock Unprinted Subscription BoxesIf you are pre-launch or just getting started on your subscription box or e-commerce program, there is no better or more eco-friendly way to begin shipping your customers’ orders. Globe Guard® boxes are always at least 60% recycled content, as well as 100% recyclable, repulpable, biodegradable and even compostable.

Professional packaging look/ Small Investment

The most important benefit they provide a startup company or product is the fact that only a minimal investment is necessary. You can select a stock, popular size from our mailer box section of our store and order a bundle of as few as 25 or 50 boxes. Adding a custom printed label provides the initial branding and you are on your way!

A partial group of subscription boxes we've runWe know many have been dreaming for weeks, months, or even years about the way their custom printed box is going to look. Some sadly discover their vision is not practical or in some cases, even printable. Using a stock box can help a company get started until the business and volume can help justify the vision.

Additional benefits of using a stock box in the beginning

Above and beyond the minimal investment mentioned above, and saving money at a time when you may have zero or little cash flow, there are other advantages of using a stock, unprinted Globe Guard ® box:

  • They make it easy to implement a packaging “plan B” if necessary. 

What if your initial box ends up being too short, to narrow, or too tall? You start out with no history about products, customer preferences or volume, so everything is essentially a guess. If you guess wrong, changing sizes is so much easier and less expensive if you haven’t already invested possibly hundreds or even thousands of dollars in a cutting die, print plates, or a minimum order quantity (MOQ) of 1,000 boxes.

  • Custom printing is inflexible. 

I often tell people the true story of how we rebranded our company six months after we officially launched. Customer feedback indicated the name was too long and our tag line and logo confusing. So before we had too much invested in our initial brand, we chose to re-brand. The less you have invested the better until you gain some of that all important customer feedback.

  • Converting to custom printed boxes is a breeze, when you are ready!  

If you have been using one of our stock, unprinted boxes, and the size is working perfectly for you, and your volume and cash flow grow, we can easily begin custom printing that specific box size for you. We can grow as you grow with a basic one color design to get started, maybe you add a second exterior color later, and then possibly you add inside print as your brand grows and you are ready to eliminate some more manually applied stickers and labels.

When is the right time to switch to custom printed boxes?

The answer varies from one situation to another mostly focused on affordability and how sure you are that you will not be making any other changes soon. Print plates cannot be modified so the goals are no regrets and no unnecessary expenses. I usually suggest waiting at least 90 days after launch or when you get up to 300 to 400 shipments or subscribers per month

As always, if in doubt, email us at Salazar Packaging or call us at 815-609-3600. We will be glad to discuss your specific needs with you.

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Inside of lid - great place to add logo or tag line

We are proud to have helped hundreds of people create packaging for their new, start-up companies. One thing most have in common is that they typically do not have deep pockets. Even the ones that are crowd funded understand that limited available funds have to cover a lot of different and often times unexpected expenses.

Inside Prints – now or later?

Printing inside of any die cut mailer is very effective. No matter how beat up the exterior of the box becomes in shipment, the interior is always free of scrapes, dirt, tape, and labels. That can make the inside a great place to place additional artwork or graphics.

The problem is that printing inside can be expensive when you are just getting started, It typically adds about 30% to the cost of any die cut mailer box, plus of course, each inside color requires an additional print plate. These costs and expenses come at a time when you can least afford them and cash flow is minimal or non-existent.

Mailer inside print made easyUpgrading and updating your boxes’ branding.

As soon as you have hundreds of subscribers and customers and some cash flow, you may be able to add inside printing to your box. This is not only done for enhanced appearance, in some cases it can eliminate insert and/or labels being manually applied.

We recently added inside print for a customer that was spending over $.25 each (PLUS LABOR) for a manually applied label. In addition to the cost, his concern was that the labels were rarely applied straight, and never applied the same way twice. Adding inside print can reduce material and labor cost and deliver brand consistency and a more professional look.

What is involved to add inside print?random repeat print dresses up mailer box interior

Just like the outside, you will need a print plate for each color. We can print virtually anything on white or Kraft board, from simple text to a rich flood coat, a random repeat print, or reverse print logo or text. Printing inside is an additional step and does add cost per box, but not as much as you may think. On a typical $.70 mailer, it would only add approximately $.20 per box

See the examples shown on this post and on our gallery and let us know if you have any additional questions. Whether we are currently running your boxes or someone else is, please contact us at Salazar Packaging or call us at 815-609-3600 for a confidential review of your specific needs.


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One color on white Min-Weight boxesCurrently shipping costs are rising much faster than profit margins for many e-commerce and subscription box brand owners. Some take the easy route and simply reduce the size and weight of the boxes they ship by simply giving their customers less.

The people at Universal Yums were determined to continue providing their customers with as much of their delicious international treats as possible. It was that commitment that first caught our attention. They asked us to help engineer a solution that would eliminate unnecessary, redundant corrugated board and it was not nearly as simple as it sounds. Eliminating corrugated board to reduce overall package weight can be tricky because you do not want to reduce the box design’s strength. As we tell people, the problem is not your three pound package, it is the thirty pound package that ends up on top of yours, that creates the problem.

A peek inside a Min-Weight boxDesign, Redesign and Testing Produces Great Results

“Every ounce counts” was the customer’s direction so we started strategically eliminating board that we thought would not weaken the box’s strength. We worked with different cut outs and a variety of board grades and quite frankly, not all of our designs satisfied the requirements. Our designers created multiple versions before we arrived at the following:

  1. Top tuck mailer that is 10-1/2” X 8-1/2” X 3-1/2” – empty weight of approximately 5.4 ounces* custom printed
  2. Top tuck mailer that is 8” X 5” X 3” – empty weight of approximately 2.8 ounces* custom printed

*NOTE- paper/board weight varies and printing ink adds weight as well so our   recommendation is always to stay well under target weight to avoid going over.

Min-Weight™ Boxes Now Available For You!

We liked this design and results so much that we decided to add these two cutting dies to our inventory of over 45 different available sizes and styles. If they are not the correct size for you, talk to us about a custom print, custom size, that will help you promote your brand while helping you reduce your shipping costs.

Contact us at Salazar Packaging or call us at 815-609-3600 if you have any questions, would like to see samples or would like to discuss your specific needs. We recently helped a customer reduce their shipping costs by $2.00 per box by keeping their box under the USPS one pound rate, and we can probably help you achieve similar results.

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Every form of mailer envelope plain or printedBranded, custom printed packaging can easily be accomplished at minimal overall costs by utilizing our line of unpadded paper mailer envelopes. It has remained a customer favorite for years for a number of very good reasons that include:

  • Low one case minimum quantities (usually between 200 and 500 depending on mailer size)
  • Unprinted is a stock item and usually ships next day (see sizes here)
  • Available white or Kraft
  • Available flat or gusseted construction for thicker, bulkier products such as clothing
  • 100% recyclable and 100% recycled content making it a very green packaging solution

3 mailers, 1 plateStart-up Costs for Custom Printed Packaging

Some hurdles for creating branded packaging are perceived but one that can be very real are start-up costs. They may include cutting dies, print plates, art charges, etc. depending on the type of product you are considering. For example – we usually estimate print plate charges for boxes at “between $400 and $600 per color”. In some situations, like a new company or product line, this may make switching to a custom print cost prohibitive.

On our custom printed mailer envelopes, the art/plate fee never exceeds $125 per color, per side. That makes it affordable for just about any company at any stage of development.

Custom Printed Multiple Sizes?

What happens when you need two or three different mailer envelopes because one size mailer envelope does NOT fit all?

If you can use the same copy and the same size on your art, we can create one print plate that fits all your sizes and minimizes your cost.

A perfect example –

They are a terrific source for beautiful infant apparel and have been a long time customer using three different size mailer envelopes. The largest is gusseted and the two smaller are flat mailers for smaller products or orders. (Note: they just added a fourth size and yes, we are using the same print plate)

They were able to design a one color, screened logo that can be printed vertically on all three sizes and look good as you can see in the attached photo. That means one size plate and only one plate charge for three different size custom branded packaging containers.

We truly work to help customers get into custom printed packaging at minimal cost. Boxes are not always the best product or solution and for those applications we have a full assortment of mailer envelopes that includes paper and poly, cushioned and not cushioned. Even if this is your first time, expect to get decades of packaging advice when you choose to work with us.

Please contact Salazar Packaging or call us at 815-609-3600 to discuss your needs and application. I can assure you we have a solution for you that is affordable and will look great!

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Skosh Box – Delivering the WOW Factor

one color on white, in and outMost of the people who contact us are not interested in purchasing shipping boxes, they are in search of unique marketing tools that connect them to their customer. In other words, they want their subscription or e-commerce boxes to stand out and create a memorable, positive experience. Whether they refer to it as increasing the WOW factor or enhancing the customer experience, the common goal is the same – to reinforce and promote the brand.

Economics, Graphic Design or Color?

Some people think they have to choose between these options because they do not realize that the cost difference between a basic one color on Kraft box and one that explodes with color is minimal. As discussed in detail in the “related post” link below, one of the greatest bargains in corrugated packaging is the second color.

There is very littlel difference in plate cost for less than 25% ink coverage compared to a flood coat design and there is virtually no difference in the box cost. Bright colors do not cost more than pastels so essentially – anything is possible. Great subscription box and not shy about color!

9-6-2 mailer box with printing inside and outOne of our most daring customers when it comes to color and design are our good friends at Skoshbox. They could pack their delicious treats from Japan in a brown box that would simply not be them. See the photos in this post and be amazed at their creativity and the boldness of the colors they select and how they use them, inside AND outside!

Our congratulations to Skoshbox for maximizing the benefit of custom printing their shipping containers!

We will gladly review your concept or design and help you determine how to achieve that maximum WOW factor and the minimum cost. Please contact us at Salazar Packaging or call us at 815-609-3600.

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50-50 longitudinal  scored pad insert dividerIs there anything more disappointing than opening up an eagerly anticipated e-commerce or subscription box package only to find everything that was carefully packed is now an unrecognizable heap? Many of our customers work very hard to create a great presentation for their customers with custom printed branded shipping boxes, color coordinated tissue, interior box graphics and a variety of other techniques, all designed to impress. However, the trip from their facility to their customer’s address can be a long, brutal trip, and what looks great going out, typically does not look so good when it arrives. Fortunately, there is a fix for that.

What are scored pad dividers?

They are typically corrugated board inserts that are designed to separate products to prevent damage or simply present better. It may sound extreme but imagine shipping a 12 ounce soft drink can with a bag of potato chips. No matter how carefully you pack them, it is very likely the potato chips will arrive crushed. If you shipped a pair of sunglasses and a tee shirt, wouldn’t both items look better if there was a partition separating them?

75-25 cross directional divider insert

75-25 cross directinal insert in stock box

What about cutting dies and changes?

The best part about scored pads is that for the vast majority of applications NO CUTTING DIE is required so they can be changed at will with no cost.

Let’s say your box has an 8” long X 4” wide packing area. This month because of the products you are shipping, you would prefer a 50/50 cross directional divider creating two cells that are each 4” X 4”. However next month you are shipping a long, small product like a pen and would like a 1” X 8” longitudinal divider? No problem, no die cost!

If you require slots, holes, rounded corner, cut-outs, etc. then a cutting die will be needed, but a simple divider as shown in the photos is tool-less.

What about colors or printing?

The two basic board color options are white or natural Kraft (brown) board. Custom prints and color are available but minimums will apply and print plates will be required.

Aside from appearance, are there any additional benefits?

Scored pad dividers ship and arrive flat and are formed as needed so they take up very little space compared to most forms of void fill or cushioning. Typically they weigh less so shipping costs inbound (to you) and outbound (to your customer) are also minimized. In some cases box sizes can even be reduced. The greatest savings, however, may be a reduction of labor because void fill can be very time consuming. Packers can usually pack and ship more boxes per hour decreasing cost and increasing productivity.

Scored pad dividers are not the best internal packaging solution for every application but for many, they can be. Except for the very largest applications, the minimum is 1,000 and depending on size, the minimum might be higher for custom printed applications.

For a free, no cost, no obligation review of your application, please contact us at Salazar Packaging or call us at 815-609-3600. We can probably create a mock up and help you determine if it is indeed the best option for you and your products.

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Have you seen the new Globe Guard Reusable Box Sealer