Posted on July 1, 2020 by Michael Boik

What’s New in Custom Paperboard Packaging?

Paperboard packaging is not a new product offering from Salazar Packaging. In fact, we’ve been selling stock unprinted paperboard cartons on our webstore for years, and have long been a provider of custom paperboard packaging as well. However, recent advancements in equipment and a number of other factors have made paperboard packaging—now more than ever—a great option for your packaging needs for a variety of applications, including product display within retail stores, or as primary, direct contact packaging that is shipped within a corrugated mailer (also produced by Salazar Packaging—see below). The following details a number of reasons why you should be excited about paperboard products being offered at Salazar Packaging.

Shorter Lead Times

Previously, lead time was always a major drawback of paperboard products. We received dozens of inquiries every week from a variety of businesses seeking paperboard packaging, but they simply could not wait the 4-5 weeks it would take to produce a custom order. Luckily, our lead times are now closer to 2 weeks on MOST paperboard product applications. This typically does not include shipping times, and remember that our lead times are always from the time we have final approved artwork.


Little to No Print Plate Costs

Most paperboard carton applications had print plate and proof costs of about $400-800 depending on the specific design. Even a 1 or 2 color design with 25% coverage would have a print plate cost of a few hundred dollars. Thankfully, now we are able to offer paperboard packaging with little or no print plate costs for most designs and applications. Both designs you see below were produced without a print plate cost to the customer.

Custom Paperboard Packaging

Lower Minimums

We have always stated a 2,500 minimum quantity for custom paperboard packaging. While this minimum is still true in most cases, there are some exceptions where we can now accommodate lower minimums, depending on the board type, (white or kraft) caliper and most importantly, size of the carton (length, width, depth). The minimum for paperboard and any other type of packaging is almost always tied to board minimums, as well as board availability (how much of the board we need to run this project is already available at the plant? How much would need to be ordered from the paper mill). The answers to these questions change from one order to the next, so timing plays an important role.


Unique Design Capabilities

At Salazar Packaging, we have always prided ourselves on being a one-stop shop for all packaging needs. We were very excited by the opportunity when one of our existing paperboard carton customers came to us seeking a paperboard insert design to protect a new glass bottle dropper within the carton. The bottle is smaller than their previous product, so using their existing carton required an insert to hold the bottle while creating a cushion of paperboard to eliminate the excess space and prevent movement. This design is only one of many that we have created for similar applications and there are very few limitations to what we can do to accommodate whatever product and needs you have.


Please Contact Us Today

Want to know more about paperboard packaging? Please contact us today. We’re happy to help you find a custom packaging solution that works for you. As always, if you have any questions, one of our branded packaging advisors is standing by to assist, with decades of experience behind them. Want to know more about custom packaging options? Please call us at 630-551-1700 or contact us via email at


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