When to choose custom instead of standard?
The trade-off between a standard box and a custom one
A standard box is quick and cheap, but rarely fits precisely. As soon as your product differs from common sizes, you pay in hidden ways: for the air you ship, for void fill, for damage and for a mediocre presentation. A custom box pays for itself as soon as one of these applies:
- Your product has an unusual size that no standard box fits snugly.
- Your shipping costs are driven by volume or weight — then every excess centimetre is money.
- The box is part of your brand experience; a snug, fitting box looks more professional than a half-empty one with filler.
- You lose products to damage because they move around inside the box.
Not sure whether custom pays off in your case? Work it out with the Box Calculator, or describe your situation — I'll simply run the numbers with you.
How to determine the right box
Three choices that together make the box
A good custom box is the sum of three choices. We make them together; here's what matters.
Flute grade and quality
The flute grade determines strength, thickness and printability. E-flute (approx. 1.5 mm) is thin and fine for retail and crisp printing, B-flute (approx. 3 mm) is sturdy and prints well, C-flute (approx. 4 mm) is the transport standard, and double-wall BC carries heavy or export loads. Which you need depends on weight, stacking and whether the box is printed. Check the strength with the Box Calculator or read the properties in the material guide.
The right FEFCO style
FEFCO is the international coding for box constructions. The classic regular slotted case (FEFCO 0201) is the workhorse, but for fragile, heavy or retail products there are smarter constructions — from crush-resistant outer cases to self-locking e-commerce boxes. See the full overview in the FEFCO catalogue.
Internal vs. external dimensions
The classic pitfall. Box sizes always refer to the internal dimensions — length × width × height of the space your product fits into, in that order. The external size follows from the chosen flute thickness. Give the external size by mistake and the box comes out just too small. When in doubt we measure together, or use the calculator, which works with both internal and external dimensions.
Small and large runs
From a first test run to ongoing production
At IVX both are possible: from a small first run — often possible from approximately 500 units — to test a new box, to ongoing large series. The minimum run varies by construction, material and production route. Die-cut advice and, where needed, a first sample are part of it, so you're not caught out and only order large quantities once you're sure the box is right.
From request to delivery
Four steps, one point of contact
Your question. You describe your product, or send a sample or photo. The more concrete, the sharper the advice.
The advice. We determine flute grade, FEFCO style and dimensions together, and I calculate the strength for weight and stacking.
Sample & approval. You get die-cut advice and, where needed, a sample, so you know it fits before ordering a run.
Production & delivery. Once approved, the order goes into production — small run or large series. We record the specifications for a smooth repeat order.
Frequently asked questions about custom boxes
Short, concrete answers to the most common questions
The price depends on size, flute grade, any printing and the run size. A custom box may seem dearer per unit than a standard one, but it often pays for itself: you ship no air (a lower postage bracket), need less or no void fill and suffer less damage. Work out your situation with the Box Calculator, or describe your product for a concrete price indication.
Small runs are possible too: custom boxes are often possible from approximately 500 units. The minimum run varies by construction, material and production route. You can start small — for instance to test a new box — and scale up to ongoing large series later. We discuss the ideal run based on your product, lead time and budget.
Always the internal dimensions: length × width × height of the space your product fits into, in that order. The external size follows from the chosen flute thickness. Give the external size by mistake and the box comes out just too small. When in doubt we measure together, or use the calculator, which works with both.
Rule of thumb: E-flute (approx. 1.5 mm) for light retail products with crisp printing, B-flute (approx. 3 mm) for sturdy, printable boxes, C-flute (approx. 4 mm) as the transport standard, and double-wall BC for heavy or export shipments (from approx. 30 kg). The right choice depends on weight, stacking height and whether the box is printed. The Box Calculator and the material guide help you on your way.
For custom boxes — printed or unprinted — allow a lead time of 2 to 4 weeks. For printed boxes that period starts after you approve the proof. Need something faster? I can often draw on the stock range of partner suppliers; within the Netherlands those boxes are usually delivered within 1 to 3 working days. For recurring orders we record specifications, so a repeat order goes faster.
Request advice or a sample
Describe your product in two sentences — I'll think along about the right box and send a sample where useful.
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