Posted on January 31, 2018 by Michael Boik

RSCs and Die Cut Mailer Boxes


While it’s true many people will make packaging decisions based on appearance, there are many other deciding factors that determine the best application for their needs. This is especially true in the debate between an RSC style (Regular Slotted Container) box vs. a die cut mailer. The potential benefits of each extend far beyond simply presentation or appearance, and sometimes there is a clear advantage to one over the other, which can be determined given a little guidance on the subject.


Assorted Die Cut Mailers

Printed RSC Style Boxes








                                                               Die Cut Mailer                                               RSC

Print Plates and Printing Capabilities


Con: Die cut mailers will require a print plate for each color used inside and outside. Expense is typically $400-600 (each) and sometimes reaching four figures.


Pro: Print plates are a one time fee, and the benefits of having the ability to print inside of the box is often a great marketing/branding tool.


Pro: Ability to print flood coverage, or edge-to-edge.

Pro: A print plate on an RSC is generally less expensive by comparison.


Con: Printing capabilities are somewhat limited in comparison to die cut mailers, including only being able to print outside of the box.


Con: No edge-to-edge print capability.

Size Options Pro: We have over 150 cutting die sizes already available, and we have the ability to make virtually any size you want, with the purchase of a new cutting die.


Con: If a custom size is needed, a cutting die will need to be purchased.


Pro: An RSC does not require a cutting die, so it can be made to your specifications, virtually any size with no additional tooling costs.
Costs (per Box) Con: Generally, a die cut mailer will cost more per box than an RSC by comparison Pro: An RSC will consume less board to produce, thus, a lower per box price.



Assembly and Closure Pro: With locking tabs, most Die cut mailers typically require no additional tape or closure.


Con: Die cut mailers can be more time-consuming/difficult to erect


Con: RSC boxes will require tape or other closure materials


Pro: An RSC is generally easy to erect in little time.


Structural Design








Pro: The construction of a die cut mailer creates a double wall of protection on 3 of the 4 sides, resulting in a strong structural container. Pro: There are many products that require horizontal presentation, as well as larger items that are simply better suited for the size flexibility of an RSC style box.


As you can see, there is no right answer in the RSC vs Die Cut Mailer debate. What works for one company may not work for the next. If you are weighing your options, you are not alone, and we are standing by to assist with your questions along the way.


The packaging world, though vast with potential options, does not always have to be navigated alone. We have decades of experience behind us to help guide your way. Have questions about RSCs or Die Cut Mailer Boxes? Please Contact Salazar Packaging or call us at 630-551-1700 for a no cost and confidential review of your packaging goals or challenges.


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