The Best Inside and Outside a Shipping Box

Retail ready shipping boxThere are companies that are amazingly good at internal packaging and can protect just about anything, shipping anywhere. There are other companies that seem to know everything they should know about branding corrugated containers whether the need is for a custom or standard RSC style shipping box or for an impressive, unique presentation box designed from a basic die cut mailer design. Few people can do both, especially with a sharp eye on the sustainability aspect of the packaging they help create.

At Salazar Packaging we do both extremely well by combining decades of experience, design expertise and the best and greenest materials available to satisfy just about any application and requirement. It is when we meet a client with what could be a complex combination of needs that we are at our best. Our unofficial motto is: If it was easy, anyone could do it.

It was during one of these tough application encounters that we had the opportunity to get to know the neat people at Orphan Espresso. They were about to launch their new Lido 2 Manual Coffee Grinder and were in need of multipurpose packaging since the plan was to wholesale the new product and to also make it available on their e-commerce store. So ideally the packaging would have to be:

  1. Attractive enough to look good on a retail shelf
  2. Sturdy enough to ship individually
  3. As ecofriendly and sustainable as possible

That could be a tough order since the grinder features glass and metal components. We soon concluded we could create a molded pulp clamshell that would provide the required protection and satisfy the green requirements for their internal packaging.

shown with lower half of molded pulp clamshellThe custom printed shipping box

Working this project from the inside out, once the internal package design was complete, we quickly recommended an end load box because compared to a standard RSC, it actually consumes less corrugated board resulting in a lower cost, and the full overlap end flaps create a double wall, making it a much stronger shipping container. FYI, this design also leaves the two largest panels on the box wide open for printing without a seam.

Speaking of printing, they were concerned they might have to go with a more expensive printing process like a litho label to properly show the glass features of their product. We showed them the box we recently printed for Uncommon Goods (photo below) and they were thrilled to be able to create a great looking (retail ready) box using only ONE color, again minimizing printing and plate cost.

One color print with screens

The End Result

A package design that is Eco friendly, protects the valuable product during shipment and attractive enough for retail use and sturdy enough to ship individually. In other words, everything on the customer’s shopping list.

For a really great manual coffee grinder, check out our friends at Orphan Espresso. For some really solid packaging guidance you can trust and afford, contact us at Salazar Packaging to discuss your specific requirements.

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Free Shipping on Pallet Wrap Stretch film

Free DeliveryWhile other suppliers charge $50, $100 or even $200 to deliver a pallet of pallet wrap film to your door, our new stretch film program provides the best stretch films at the lowest possible cost with absolutely no additional cost for shipping.

Great Variety and Great Prices

Whether you wrap pallet loads of product on a high speed wrapper with machine length rolls, hand wrap pallets, or bundle products with hand wrap film, we have a film for your specific application. All films are not created equal and our decades of experience will help you select the best and most economical film for your needs.

Paragon Torque Hand Stretch film rolls in stockCheck out our green packaging store and see how easy it is to get the right film and the best possible price. Please contact us at Salazar Packaging or Globe Guard Products with your questions and we will be glad to help you review your film usage in an effort to minimize cost and maximize film performance.

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Front lock -drop front (front opens up)We make great looking custom mailer boxes in a variety of different designs since customer requirements vary greatly. The designs we use include top tuck, Indestructo top tuck, front lock and our Eco Mailer Box™ design. We also offer a great selection of feature options for each box mailer design, and these include easy open tabs and cut outs, side dust flaps, and flat bottoms for inside graphic purposes.

Mailer Box Design versus Feature Option Dilemma

The problem is that not all feature options are available on all mailer box designs. In some cases, they are impractical and others are simply impossible. For example, if you really want to print the bottom inside of the box, you cannot use an Indestructo style mailer because it creates tabs that fold into the bottom, covering up your copy.

Another exampEco Mailer box (back opens up)le is the Eco Mailer Box™ style that uses a minimal amount of board and makes it easy to access the product being shipped. However, if you prefer a front lock design feature for security reasons, the combination is incompatible. For a recent application where a customer insisted on having easy access and a front lock design, one of our designer friends came up with a whole new design option we have never made before.

The Front Lock – Drop Front die cut mailer box

It is first and foremost a front lock mailer with dust flaps providing the greatest amount of security and strength. However, the bottom front panel of the box does not tuck into the sides as it usually does, making it possible to create a front panel that is separated and drops down for easy product access.

This may not appear to be a huge difference, but it was important for our customer so it was important to us. It is a bit of a hybrid box, taking from three other box designs to create a whole new offering and it is perfect for this and any application requiring security AND easy access.

A Wide Selection of Packaging Can Do’s! Traditional top tuck with easy open notch and dust flaps

Whether the need is a low volume requirement for stock, unprinted mailer boxes or a truckload of custom printed boxes, we can do it for you. Whether it is a simple basic design you need, or something different like our new Eco Mailer Box or Front Lock – Drop Front design, we can do it for you.

We may not have thousands of stock sizes of plain, unprinted boxes but we do offer one of the best varieties of ecofriendly, custom printed and branded shipping containers to satisfy YOUR specific needs. Please contact us at Salazar Packaging for a no cost, no obligation and confidential conversation about your specific goals and objectives.

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A partial  group of subscription boxes we've run

I am not sure if we have helped create more subscription boxes than any other packaging company, but I am quite certain we are probably in the handful at the top of the list nationally. The photos included in this blog post as well as the ones scattered around our web sites show the wide variety of boxes we have created including candy, feminine hygiene products, razor blades, office snacks, kids crafts, infant care, vacation programs and every type of sampling program imaginable.

Two side, one color print on white inside and out

We work directly with the brand owner, ad companies, designers, and occasionally with the fulfillment company that is responding to a client’s request. The pressure is on to make our boxes unique and memorable and that is exactly what we do so well.

Two colors on printed light gray interior

Unique Capabilities Create Unique Boxes

The variety of designs we help create include:

  • Flexographic print inside and outside up to four colors
  • Offset litho label designs with photo quality, multi-color images
  • Paper board folding carton inner packaging
  • Rigid box inner packaging
  • Inserts for product retention and protection such as molded pulp, die cut corrugated, molded foam and void fill solutions

One color out, one color in, on Kraft

Why Customers Trust Us with Their New Subscription Boxes

  • Decades of packaging industry experience and years of subscription box experience.
  • Most of our boxes are made with 100% recycled content and are 100% recyclable, biodegradable and even compostable.
  • Personal service
  • Quick response (most first time orders ship two weeks after approved art)
  • Custom printed packaging for not a lot more(and in some case, less) than plain, unprinted boxes

Harry's one color on white printed inside

Whether you are launching your first box or perhaps ready to step up to a new design, we are more than willing to assist you in the process. We will supply you with anything and everything you need including box samples, ink swatches, art templates and final proofs requiring your approval to make sure you are absolutely thrilled with the end result. Please contact Salazar Packaging for a confidential discussion of your needs.

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black flood coat withs suitable for framing graphicsWe are widely known for the beautiful custom printed boxes we help our customers create. We have become very proficient at utilizing the standard flexographic print process to its maximum potential to produce unique, eye catching and colorful results. However, what happens when flexographic print process is not enough? What do we do when the customer wants something that is completely out of the ordinary? That is when a little known process called litho labeling can deliver results not possible on a standard flexographic press.

The Limitations of the Direct Print Flexographic Process

You can get more info from the first listed “related posts” below but flexographic corrugated printing is a “direct print” process. We apply the ink directly onto the corrugated board utilizing flexible print plates.

Corrugated board is an industrial grade paper, NOT a fine printing paper as you might see on a brochure or even on a paper board box. The board surface and porosity of corrugated paper is going to differ from that of fine paper, making it impossible to create identical results. This is most obvious on color consistency, especially on dark, high ink percentage colors.

In addition, for each color that is going to be printed a flexographic press requires an individual print plate that typically costs between $400 and $600 per color. That makes 4, 5 or more color work very expensive in terms of initial costs, especially if you need for example, packaging for multiple colors, flavors or products.

litho label box with photo quality imagesThe Litho Label Process

The litho label process is completely different because it is NOT direct. We print customer copy using an offset lithography process onto fine “litho” paper which is later laminated to corrugated board, before the board is cut or converted into boxes.

This permits truer colors, multiple shades and even different types of varnishes and finishes. Sharp vibrant colors become easy and photo quality images are possible. This can make art much more effective in terms of pop and sparkle for retail and/or premium shipper applications.

What is the down side of litho labels?  Quite frankly because of the multiple step process, they can be quite expensive, especially on short runs. While we routinely run 1,000 minimums on our flexographic print jobs, we rarely can consider a litho run of less than 5,000 and it really becomes much more affordable at 10,000 or 20,000. Several factors come into play including box/label size but we can quickly help you determine if litho labels are a viable option for you.

Ideal for POP counter top displaysCombining Litho Labels and Direct Flexographic Print

Litho labels are not an all or nothing graphics option. Another, less expensive creative approach is a partial or spot label that can be very effective, especially when it is combined with direct print on the same box. This provides great flexibility and terrific appearance at the lowest possible cost when constant information can be direct printed and product specific labels showing off styles or color photos can be added to help shoppers distinguish product on the shelf.

Please contact us at Salazar Packaging for a confidential application analysis to determine the best way to help you accomplish your branding and cost objectives.

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A wide assortment of available  die cut corrugated mailer boxesWe are thrilled any time we can use one of our available cutting dies to run boxes for a new customer, because we are able to save them money. In some cases, a lot of money. We have many popular styles and sizes available and are always looking for new sizes to add to our arsenal for our customers’ convenience. We are pleased to offer the following new four sizes:

7-1/2” X 5-1/2” X 4” Top Tuck Eco Mailer™ – this box is rather unique because of its 4” high capacity and unique design. When the lid is opened and lifted, the back of the box opens up to allow easy access to the product being shipped. (See related post below) We like this box so much that we have added it to our Globe Guard green packaging store and it is available unprinted in one bundle quantities.

15” X 10” X 4” lock front mailer – large capacity and high profile. It features locking tabs and side dust flaps for extra strength and security.

9-1/4” X 9-1/4” X 4” lock front mailer – This size is very versatile allowing high profile products and inner packing to fill the extra tall capacity.

18” X 8” X 4-1/2” lock front mailer – a mailer with unusual rectangular dimensions, ideal for cylindrical and long products. Also features locking tabs as well as side dust flaps.

7.5 X 5.5 X 4 Eco Mailer boxCustom Printing is Always an Option

The above and any of our die cut mailers are available custom printed in a very low, 1,000 box minimum. This not only includes the standard stock sizes we feature on our store but countless others that we have ready to use cutting dies, saving you time and money.

These boxes are all available in white or natural Kraft (brown), inside and/or outside. Custom printing can include flood coats and any graphics you want to communicate to your customers, inside and outside of the mailer box. Custom printing can be relatively inexpensive and the ideal way to eliminate costly labels while reinforcing your brand.

As always, please do not hesitate to contact Salazar Packaging or Globe Guard Products with any questions regarding your specific needs or project.

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airpouch - peanut picI admit there are some applications and situations where the other two (far less green) products might bring some unique benefits to the table. However, that is not the case for most customers. Unless your packaging operation is located next door to your bubble or peanut supplier, and can have them delivered for free, on an as needed basis, chances are your increased shipping and storage costs probably exceed any performance or application advantage they might have to offer.

The Basic Problem with Most Void Fill and Cushioning Products

Most of these packaging products are bulky and take up a lot of space. That may be good within the box you are shipping but it is bad almost anywhere else. In an effort to minimize that negative impact, bulk packaging can be made thinner or smaller, which means you have to use more of it to get the job done. It also results in increased inventory needed to satisfy your requirements: more bags of peanuts, more rolls of bubble.

How Inflatable Products Are Different

Our inflatable pillows or our bubble on demand systems make product as you need it so it is much more efficient to store or ship. We can even vary the amount of inflation, increasing it to maximum capacity and minimizing the amount of void fill or cushioning product you need to use. Keep in mind most inflatable programs also greatly reduce labor expense compared to messy or more manual packaging options.

The photo above truly demonstrates that difference with the one case of air pillow product being the volume equivalent of all the bags of peanuts shown in the picture.

Tubular shaped bubble on demand systemMore Inflatable Options than Ever Before

The other thing that makes our inflatable packaging products different is the great deal of versatility it offers, so we can basically tailor the product for a customer’s specific application and desires. Examples:

Format – air pillows or continuous bubble on demand. Our air pillows are available in a variety of sizes and film thicknesses. The bubble can be in a honeycomb pattern or in a tubular form.

Film types – as the concern for the environment continues to grow, we offer more options than most products:

  • Standard clear film, 100% recyclable
  • Tinted biodegradable film – also 100% recyclable
  • Opaque recycled film – recycled content and 100% recyclable.

Equipment required

Yes, an inflatable product requires an inflating piece of equipment. The good news is that no large equipment investment is necessary. In fact, packaging as few as fifty boxes per day may meet low cost or no cost equipment programs requirements.

That means it does not impact your capital equipment budget and that repairs and eventual replacement will not cost you anything.

Are inflatables right for you?

There is only one way to find out. Please contact Salazar Packaging for a no cost, no obligation application analysis to determine what option is best for you. If inflatables are not the recommended product, we can assure you, we have several options to offer that will prove to be a cost reducing, greener, step forward compared to other available packaging products.

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best priceWe spend so much time creating beautiful, custom printed, branded boxes that sometimes people forget we also carry unprinted versions of our Globe Guard® RSC style and die cut mailers in stock. This makes them available in small order quantities and at pricing that is competitive with some of the national internet and catalog companies offering less green products.

Our unprinted boxes are also a great way to get a subscription box program or web store started (usually applying printed labels to the box) until volume can justify the minimums and cost of custom printed boxes.

Packaging Sale Items

The items we select for our sale category are always a minimum of 10% off and more. Discount codes and volume discounts still apply, making some of them a real bargain. The items currently on sale at include:Wide Variety of Globe Guard Shipping Boxes

  • 5” X 5” X 5” RSC cube shipping box ideal for candles and other small products
  • 8” X 6” X 3” RSC shipping box – another unusual size that is great for shipping small low profile products
  •  9” X 6-1/2” X 2-3/4” top tuck, die cut mailer. This is one of our most popular sizes, used extensively by subscription box companies because of its size and low shipping weight
  • 16” X 16” X 16” RSC shipping box. One of our largest and most popular cube shipping boxes.

Packaging Close Out Items

One of my favorite old guy sayings is “they can’t all be pearls” and that is an accurate way to describe some purchasing decisions we have made along the way. These are items that we have decided to remove from inventory and are eager to sell out the remaining stock so the savings in this category range from 20% to as much as 50% below our normal list prices.

At present time, the items in this category include:

  • 11-3/4” X 8-3/4” X 8-3/4” RSC style shipping box – this is a great size for printed material but it is simply not selling to our customers
  • 24” X 18” X 10” RSC style shipping box – You will not find a better price anywhere on a box this large.
  • 20”, 45 Gauge, Gensys high performance pallet wrap stretch film with 10,000 feet per roll. You can buy the entire pallet for $49.00 per roll and we pay the freight!
  • 7-1/4” X 12” white, unpadded paper mailer.

Closeout items are subject to inventory quantities on hand and in most cases will only be available as a special order with minimums.

New items are added to both categories often as inventory and business fluctuates so if you are a bargain hunter, we would suggest you check in regularly. We have also been known to offer additional discounts to customers willing to take “all available stock” on any item.

Please don’t hesitate to call us at 815-609-3600 or contact Globe Guard Products with any questions.

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Purchasing pallet wrap films made easyWhether you prefer to call it pallet “shrink wrap” or more accurately, pallet “stretch wrap” (because it requires no heat exposure), pallet wrapping with plastic is not new. I will have to confess I was selling pallet wrapping films and equipment several decades ago.

What is new is some of the exciting new resin technology and manufacturing processes that are producing amazing films that are containing loads during shipment with half of the plastic resin it once took. Is that green? Most people will agree that until a better product or process is developed, “source reduction” combined with recycling is the best way to minimize usage.

Serving the Educated Pallet Wrap Buyer 

The other thing that has changed is that most of the people buying stretch film are fully informed and sometime understand films better than some of the people selling them. They are totally familiar with their equipment, how much it elongates film, what type of loads they have (A, B or C) and what gauge is needed to get the palletized product from point A to point B at the lowest possible unit cost.

In many cases they have undergone rigorous film testing and do not feel the need to go through that whole process every time they are ready to place an order. They have a firm grasp on their needs and simply want the best possible price and an easy way to place their orders.

The New Pallet Stretch Film Page on Globe Guard

We have worked very hard to take a lot of the cost out of supplying pallet wrap film to our customers and through a special agreement with the industry leading manufacturer, we will be offering their films leading at the lowest possible prices through our easy to use Globe Guard green packaging store web site. Reorders are a few clicks away whether you prefer to use a credit card for your purchase or require invoicing against a purchase order.

Which of Our Films is Best for You?

If you have a question, need to discuss your unique needs, or perhaps you simply want to try a sample roll of one of our new film formulations, you will be able to communicate directly with our industry expert and program manager who is more than qualified to answer any questions.

Coming soon!

No later than March 1st you will see our initial offering of films and we think you will be surprised by the quality, the pricing and by how easy and convenient we make the process.  Stay tuned!

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What’s Your Price for Custom Printed Boxes?

QuestionIt is a common web inquiry or the opening question by someone calling our office. I often joke that is much like walking in a shoe store and asking for their price for a pair of shoes or entering a car dealer and asking how much a car will cost. Life would be far simpler if it was that easy and that quick.

The fact is that in order to give you an accurate price with no surprises at the end, we do have to ask a number of seemingly detailed questions. The process is also designed to give the inquirer a better idea of the options available to them. An appreciative “oh, you can do that” or “I want that” makes it all worthwhile. A perfect example is inside printing. Most people do not realize that printing on the inside of a box is even possible and surprisingly affordable.

The factors that determine the price of a custom printed box:

Box style – do you need an RSC (regular slotted container) or FOL (full overlap) design? Or do you want more of a presentation box like a die cut mailer with a hinged lid that opens up like a cigar box? If a die cut mailer is what you need, there are several styles available for you. (see last “related post” link below)

Board grade – though most of our RSC boxes are 32ECT and most of our mailers are made of 32B board, the variety of boards we offer is much larger. Micro flutes (E and F) are much more popular now as customers work to create boxes that are as decorative as they are functional.

Board Color – board is available in brown (natural Kraft) and white and we can create any inside combination you may want. Kraft out and white in? No problem. White inside and out? Again, we can deliver.

Printing – this is the part we love because it enables customers to create their very own look. In many cases art has not been fully developed and that is OK. All we really need to know initially is how many colors, and inside and/or outside?

Quantity – More than any other single factor, the size of the order most influences the price of the boxes. Our minimum on most boxes is 1,000, but customers are usually surprised when they see how much less expensive a run of 2,000 boxes can be.

Is  Buying Custom Printed Boxes Overly Complicated?

Not at all but it is detailed if you want to do it right. Perhaps that is why so many box suppliers recommend against it. They simply don’t want to mess with it because it is time consuming and honestly, they don’t trust themselves or their companies to do it correctly.

Custom printing is so very gratifying for us and our customers. We occasionally receive a note from a customer about their plain/unprinted boxes but we routinely get emails and phone calls from customers who LOVE their new custom printed boxes. It is great to know how excited and pleased they are and the amount of time and detail it took to get there, is quickly forgotten. Two things to remember:

Custom printed boxes are much more affordable than you probably think.

Custom printed boxes are more impressive than you can imagine.      

The key is to have the right partner and we believe we are. Please do not hesitate to contact us at Salazar Packaging or call us at 815-609-3600 if you have any questions or would like to discuss your project.

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Have you seen the new Globe Guard Reusable Box Sealer