stock, standard and custom cooler boxesShipping perishable foods and pharmaceuticals can be incredibly challenging especially from an environmental perspective. It seems the only products that are readily available are either laminated multilayer configurations or EPS (Styrofoam) that are either not reusable, not biodegradable, or not recyclable.

A Truly Biodegradable, Insulated Shipping Container

Our Globe Guard® Cooler Boxes are made of two basic components that are not laminated together and can be easily separated for recycling or reuse. The two components are:

  1.  A stock or custom corrugated RSC style shipping box that is typically made of our Globe Guard® 100% recycled content board but is no less than 33% recycled content board. The box is designed to be reused or can also be recycled, but will biodegrade in almost any landfill environment.
  2. Removable, biodegradable foam inserts designed to insulate your product and coolant on all six sides. These inserts are made from non-GMO corn starch and can be recycled or reused by removing them and installing them in a new corrugated box to extend their life cycle. If disposal is necessary, they can be composted and will biodegrade or dissolve in water.

Stock Size Pre-Assembled Cooler Boxes

For our initial launch we have four popular sizes in stock as shown on our store, ready for immediate shipment. They are available in a low, one case minimum and the cooler boxes per case vary from 2 to 4, depending on the size. All four sizes have 1-1/2” thick foam. Other foam thicknesses are available on a custom order basis. These STOCK sizes are:

8” x 8” x 8” RSC box size with a usable cavity ID of 5” X 5” X 5”

10” x 10” x 10” RSC box size with a usable cavity ID of 7” X 7” X 7”

12” x 12” x 12” RSC box size with a usable cavity ID of 9” X 9” X 9”

12” x 10” x 8” RSC box size with a usable cavity ID of 9” X 7” X 5”

Standard Size Unassembled Cooler Boxes

These sizes are not in stock but will ship within two weeks of order. They also include 1-1/2” thick inserts and can be quoted with other thicknesses as well. The minimum for this standard size group is 200 cooler boxes per order, or 100 per size. Even though assembly is available and optional, we find that most customers buying in this quantity prefer unassembled cooler boxes to reduce shipping and storage costs. These STANDARD sizes are:

9” x 9” x 9” RSC box size with a usable cavity ID of 6” X 6” X 6”

11” x 11” x 11” RSC box size with a usable cavity ID of 8” X 8” X 8”

14” x 14” x 14” RSC box size with a usable cavity ID of 11” X 11” X 11”

16” x 16” x 16” RSC box size with a usable cavity ID of 13” X 13” X 13”

8” x 6” x 5” RSC box size with a usable cavity ID of 5” X 3” X 2”

10” x 8” x 6” RSC box size with a usable cavity ID of 7” X 5” X 3”

12” x 12” x 10” RSC box size with a usable cavity ID of 9” X 9” X 7”

14” x 10” x 8” RSC box size with a usable cavity ID of 11” X 7” X 5”

image001Custom Size Unassembled Cooler Boxes

These are truly custom, made to order RSC cooler boxes and can be just about any size you want them to be, assembled or unassembled, typically shipped within three weeks, even for custom printed, branded boxes.

The minimum is 500 cooler boxes for an unprinted box, and 1,000 for one that is custom printed. They are available in Kraft or white, in any board thickness you need as well as any foam insert thickness your application requires

We can even create a die cut mailer cooler for you, if a presentation style box will serve you better than a standard RSC style shipping box. (see “related” post below)

What is your temperature controlled packaging challenge?

We understand almost every customer and application are different so we are eager to learn about yours. Please contact us at Salazar Packaging or call us 815-609-3600 to discuss your specific needs.

Related post:

Pet Gift Box exteriorOur office is filled with dog lovers so we were all very excited to work with Pet Gift Box on their new box design. Check out their neat web site

The program owner had some great ideas and we were eager to help bring them to fruition. You can see from the photos on his site as well as by the ones included in this post, he ships an ecofriendly Globe Guard® custom printed box and includes a personalized label with the pet’s name on it. It is those little touches as well as the quality products he encloses that make this box a great deal and a perfect gift for that pet lover on your holiday shopping list.

First Step – determine the correct and best size

I admit this is a challenge, especially for a new box and product that changes monthly. However, they selected one of our very popular stock box sizes 12-1/4” X 9-1/4” X 4” high. Using a “semi-custom” size enabled them to save money by not having to buy their own $800 or so cutting die, and it also saved time.

List of contents and personalized labelSecond Step – create art and print specs

Once the box size was decided on, as well as the board grade and color, we provided a die line for use in their art layout. When they asked for help with the graphic design, we were able to recommend a talented, experienced graphic designer from our short list of people we recommend. Remember, today most graphic designers are well versed in web design, but not all have any packaging experience.

Pet Gift Box chose a natural Kraft (brown) box and a standard blue for great contrast and a sharp look.

Goodies enclosedThird Step – Create a print card/proof

Customer review and approval is an absolute requirement to make sure they are thrilled with the end result and there are no unpleasant surprises. Within a few days of signature we had their print plates made and their first order of custom boxes shipped about one week later.

This may sound easy, and honestly, it really is when you have the right partner to guide you through the process. Please contact us at Salazar Packaging or call us at 815-609-3600 for a no cost, no obligation review of your new box design, or perhaps your redesign of an existing subscription box. If your volume has grown to 300 to 400 subscribers per month, this a great time to eliminate costly labels with beautifully printed boxes for your subscription program.

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  • Filed under: Salazar News
  • Local Color Collection Coaster setNo duplicate gifts! Is there anything more frustrating than to give a gift to someone on your shopping list, only to find out they already have one, or two or maybe even three? If you are still looking for the perfect gift for that person, there is a new site online where I can almost guarantee you will find something for them that they don’t already own.

    Check out to see a wide variety of attractive and unique gifts ranging from coasters to flour sack towels, all featuring eye catching citrus crate label art which originated in Florida. Local Color Collection has reproduced this art on high quality products that are sure to please and not be found anywhere else.

    Semi-Custom Packaging is the Answer

    How do you select packaging for a new product line without historical order or size data to work from? For LCL the best option was to select three sizes from our long list of available cutting dies for mailer boxes. This not only saved time, they also saved money by not having to buy custom size cutting dies until they are clearer about their future requirements in terms of size, volume and construction.

    Local Color Collection 2 sided printThis enabled them to purchase printing plates for each of the three different sizes, with printing inside and out. The outside is a very attractive white on Kraft for a natural look and the inside is their logo scattered in a random print, green on a white background. The end result is a sharp looking shipping box that is almost as memorable as the product inside.

    For that unique gift, check out the cool site for Local Color Collection and for a company that can help you create great looking branded packaging, at the lowest possible cost and as quickly as possible, please contact us at Salazar Packaging or call us at 815-609-3600.


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    Blue Jean BoxFor people who want designer jeans and accessories but don’t have time to shop or prefer to avoid the hassle of a crowded mall or overpriced specialty shops, is the place for you. Check out their neat web site and the great looking products that are only a mouse click away for you.

    Unique E-commerce Packaging Requirements

    The nice people at Blue Jean Box wanted a green, ecofriendly shipping container so it is not unexpected that they would select Globe Guard® boxes with our 100% recycled content, 100% recyclable corrugated board. Even when we upgraded their board to 200# test, we were able to keep the overall construction as green as possible.

    Since their products and orders tend to be larger, they also required a custom size box that is 24”x16”x4”. The onetime cutting die cost was relatively insignificant when they determined the larger size box would enable them to avoid shipping multiple boxes to the same location while keeping the clothing unwrinkled by shipping them in overstuffed boxes.

    Box closed with handleInside Only, Custom Printing

    Blue Jean Box is the latest customer in a growing trend to print the inside of a die cut mailer, instead of or in addition to printing the outside. As I have said many times, the outside of any box being shipped tends to arrive looking dirty and beat up. By printing on the inside, especially on the inside lid as the Blue Jean Box people did, they are sure their message will not conflict with tape, labels or road grime.

    Carrying Handle Optional

    Since a box that large and potentially heavy can prove difficult to carry, we designed the container with an optional and removable plastic handle. (See photos) Easily and quickly inserting the handle into die cut slots make the box easy to lift and carry like a small suitcase.

    Semi-custom versus Fully Custom Shipping Containers

    Our semi-custom program uses stock size cutting dies and predetermined board weights to create low volume packaging (usually 1,000 to 5,000 boxes) without the delay and cost of custom tooling.

    However, when you go fully custom like Blue Jean Box, you are able to select the exact size you need, the board weight that your product requires, and chooses from a long list of available options that will make your packaging perfect for your application and customers.

    If you have any questions regarding shipping clothing or any soft goods, please do not hesitate to contact us at Salazar Packaging or call us at 815-609-3600 for a no cost, no obligation, and confidential discussion of your needs.

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    Inside Sub Comm Interview

    megaphoneSubscription box owners have some tremendous resources and typically they are very eager to share information, and even suppliers with one another. That is at least part of the reason we have become so well known within that market, as one company who we have made boxes for recommends us to another.

    One of the best resources I have just recently become aware of is Inside Sub Comm (the business of subscription commerce) where they feature interviews with a wide variety of different subscription box program owners and companies who serve those owners.

    We were pleased to have been recently selected for a supplier interview and if you are interested in learning more about Inside Sub Comm or reading our interview, please click on this link.

    If you have any questions about designing or re-designing your own packaging for any form of e-commerce, please contact Salazar Packaging, or if you prefer, call us at 815-609-3600. We will be glad to confidentially discuss your specific application.

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    14-About-Us-Page-Revamp_wider_r8_c1We try to make gratitude a year round attitude but like everyone else, we tend to focus on it a little more as the holiday season approaches.

    Last weekend, we had the opportunity and privilege to volunteer at a great organization named Feed My Starving Children. I cannot do justice describing the marvelous work they do so I urge you to check out their web site at There are millions of children starving or malnourished around the world and FMSC, works to provide specially formulated food “Manna Packs” to over 70 different countries to help feed the kids in desperate need.

    Volunteer Help

    In addition to obvious cash donations which BTW, $.92 of every dollar received is spent on their food programs, they also do something rather unique by encouraging volunteers help to do the packing. People, regardless of age or experience, are quickly taught how to fill and seal the food bags, which are then packed into boxes for distribution to the children in need.

    Harmony carefully filling with Lenora supervisingThe “shift” is only two hours long, but it is most gratifying to be able to contribute in such a unique way. My wife/partner Lenora and our seven year old grand-daughter also volunteered and I can tell you we not only had a great deal of fun (the rock music playing in the packing area helped) the atmosphere was so inspiring, especially for our little one who can’t wait to do it again.

    Give Thanks

    We have much to be grateful for and as year-end and Thanksgiving approach, we hope you will consider supporting this wonderful organization. I am told we are not supposed to give because of the way it makes us feel, but I can tell you it feels great!

    Related post:

    Shakestir boxWe have been working with e-commerce and subscription based companies for over five years and are thrilled have helped create many great looking boxes for a wide variety of product and programs. This includes everything from DIY jewelry, cold pressed juices, socks, kid’s crafts, candy, underwear, shaving gear, and every imaginable type of snack food.

    We have done so many subscription boxes that it is now very unusual for us to do a “first” for a box in a market that is new to us. However, we recently experienced one of those rare occasions with a neat new company named Shakestir, and their extraordinary cocktail in a box delivery program.

    Most people can cook, but very few are chefs. That is not too dissimilar from people who mix drinks and the talented people who go far beyond “gin and tonic” and create wonderful concoctions using a variety of liquors, ingredients, and garnishes. The hassle has always been coming up with the perfect ingredients and knowing how to blend them.

    Shakestir takes all that effort out of the process and for now, only if you live in the NYC area, will deliver your cocktail kit to your door, COMPLETE with everything you will need (including fruit and garnishes) to help you prepare a delicious cocktail created by a professional leading mixologist, using only top shelf liquor and ingredients.

    Unique Subscription Program – Very Unique Packaging

    The tall die cut mailer is relatively basic, though the printing inside and out makes a great presentation. The biggest hurdle to overcome is the variety of bottle sizes and shapes that this box would have to accommodate so we created a two cavity, wraparound scored sheet, designed to isolate and protect each ingredient bottle. In addition we had to create a divider that could separate heavy bottled goods from potentially delicate fruit or garnishes.

    Each subscriber box each month is likely to be different, so the package design had to be flexible and versatile. Of course it also has to be eco-friendly and attractive.

    Check out and if you live in the NYC area and would like to give it a try, please feel free to use promo code DENNISISP at check out for a 10% discount.

    If you would like to discuss your subscription box program with a company that is experienced and understands e-commerce and subscription commerce, please contact us at Salazar Packaging or call us at 815-609-3600.

    customer or season specific messageIf you are one of the many subscription box or e-commerce companies using die cut custom mailers to ship your product, you may have encountered a need for a way to prevent an item from getting lost within the box. It is relatively easy for paper work, a gift card, an invoice, or perhaps a business card or thank you note to get mixed up with the items being shipped, the loose fill, or other ancillary packaging.

    The perfect way and place to get the customer’s attention

    We have always said that die cut mailers, compared to standard RSC shipping boxes are more of a presentation box than just a shipping container. A die cut mailer opens up, with a hinged lid, similar to the way a cigar box opens. There is a reason why that inside lid of a cigar box is always highly decorated – because it is so obvious for the consumer to see. That makes the inside lid of any die cut mailer an ideal place to print copy and it is also the perfect location to apply an adhesive pouch – where it cannot be missed and is certain to get the consumer’s attention.

    Can't miss it insert on inside mailer lidAdhesive Pouches and Packets

    They are not shown on our store YET, but we have a variety of clear, unprinted stock sizes that are readily available by the case. The sizes range from the very popular business card size, to an 8-1/2” X 14” legal size. There are also a variety of vertical (example – 4-1/4” X 11”) and horizontal (example 5-1/2” X 8-1/2”) pockets and even a half round designed to hold a CD or audio disc. All have a convenient peel and seal strip for easy application to your mailer box.

    For those who want a can’t-miss custom message or color, we also offer custom printed adhesive pouches with a minimum starting at 5,000. Spot or full litho graphics can be printed up to seven colors. The possibilities are almost unlimited when added to or used in place of inside printed mailers.

    stock business card size pouchPlease contact Salazar Packaging or Globe Guard Products if you have any questions or interest. We are very excited about this new product line and we can assure you that you will be hearing more about them in the days ahead.

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    How to Reduce Shipping Weight and Cost

    Corrugated Board FlutesAs a result of dramatically increased shipping rates and costs, many shippers today are looking for ways to reduce the overall package weight in an effort to reduce the shipping cost. Being over or under a particular weight (for example, one pound) can make a shipping cost difference of over two dollars per package. That is huge if you are shipping thousands of boxes per month.

    After working with dozens of companies to accomplish lower shipping rates, we offer these possible solutions:

    Using the best shipping container for your product

    Here I often use clothing as an example because I don’t understand why anyone would want to use a box if they don’t have to. The fact is that most clothing and soft goods can ship in paper or plastic mailer envelopes, eliminating the box as well as the void fill or other ancillary packaging that may be required. Keep in mind, void fill not only adds purchase, inbound shipping and storage cost, but also adds weight.

    E-flute board for clean, retail look, NOT weight reductionRight sizing can lead to big packaging cost and weight reductions

    This may be the most obvious advice I provide but you would be surprised at how many shippers are using boxes that are too large because that size is a “stock” size for their supplier, or because they occasionally get a larger order that requires the larger shipping box. For example, our 7x7x2 die cut corrugated mailer box weighs 3.1 ounces. Our smaller 5x5x2 mailer weighs 2.1 ounces. Using a smaller, size appropriate corrugated box also results in inbound shipping cost and storage savings.

    Weight reduction by using thinner board

    If you would like to use a smaller flute board to make your boxes to make them look more retail and less industrial, that is a great idea, but in most cases it does NOT reduce the weight of the box.

    We have been involved in many cost analysis and in almost all cases, there is no significant weight reduction. In some cases there could actually be an increase in weight when you go from C flute to B flute or even from B flute to E or F flute corrugated board. As the photo shows, even though the overall board thickness is reduced because flutes are smaller and thinner, there are more of them, resulting in approximately the same weight.

    However, we have been able to deliver significant weight savings by modifying the construction of the board and using either thinner paper inside or outside or even a lighter medium. This can get rather complicated but suffice to say that we know how to accomplish the objective without compromising the container’s integrity or the graphics that are printed on it. Keep in mind that for some “non-standard” paper and board combinations, minimums may apply, but if you are shipping more than a few thousand boxes per month, you likely qualify for the lighter board combinations.

    Weight reduction by container design

    We have done much work in this area reducing the overall board usage (square inches minus scrap) significantly by using an Eco Mailer Box design or Indestructo design but neither of those are guaranteed to reduce the weight of the finished box. Front lock versus top tuck, dust flaps versus no dust flaps, can all impact shipping weight if it is done properly. (See related posts at the end of this post)

    Remember that the container being used still has to keep the product safe as it ships from point A to point B and that probably none of these options are a stand-alone solution. No two shipping and packing applications are identical so we will review the overall application to determine the best way to reduce the desired weight. In many cases, substantial weight reductions are best made possible by using a combination of box manufacturing techniques.

    Contact Salazar Packaging or call us at 815-609-3600 for a no cost, no obligation review of your needs.

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    Gift look, two color exteriorWe have helped many companies create boxes for their E-commerce or subscription programs and one of the things we most appreciate is the uniqueness of their graphic design.

    Some prefer the understated elegance of a minimalist design while others choose a graphic design that explodes with color and complexity. The Bride Box is one of the latter with a design that typifies the WOW factor.

    The celebration begins with the box!

    Check out and you will see a great gift idea for that newly engaged lady you know. Each month she receives, gifts, samples, and information that is sure to be appreciated and useful as she prepares for the biggest day of her life.

    It was important for the nice people at The Bride Box that the box being shipped to the new subscriber celebrates the event, consistent with the excitement and happiness the bride-to-be is experiencing. Congratulations to them on a job well done!

    Beautiful two color interiorProducing a great looking mailer box.

    I will admit the first time we saw the graphic design concept (check out that interior print) we knew it would be challenging. However, we were sure with a few tweaks we would be able to deliver the look the customer was striving for. The team effort, including our graphic artist, our plate maker, and our printer made sure every detail was covered so the end result would be perfect.

    If you are looking for that great gift idea for a bride-to-be, please visit The Bride Box web site to learn more about their program. If you want to create a great looking box for your subscription or e-commerce business, please contact Salazar Packaging or call us at 815-609-3600 for a free and confidential review of your needs.

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    Have you seen the new Globe Guard Reusable Box Sealer