rigid setup box services
Rigid Boxes (also called “Set-Up Boxes”) are a very common type of packaging and they are often associated with luxury products. Rigid boxes are typically four times thicker than an average folding carton and are not usually printed on directly. They are instead wrapped with paper that can be as plain or luxurious as desired.
Rigid boxes, as the name suggests, are rigid and sturdy. Think of the classic “Shoe Box”. If you’ve ever purchased a nice pair of shoes or heels, they will have been packaged in a rigid box. Board games are another classic example of rigid box packaging. iPhones and other high-end electronics use rigid boxes, as do many beauty and high-end food products and spirits, just to name a few.
Rigid box packaging is not simply about luxury. It can (and should) be considered in lieu of a folding carton when protection and durability during transport and the often rough retail environment are major factors. In addition, in the consumer’s home, where repeated use and storage of the product in the box is an asset, rigid boxes will add value for your customers.
How Are Rigid Setup Boxes Made?
Most of the processes are either done by machine or hand or various combinations of the two, depending on the specific manufacturer.
Rigid boxes start out as sheets of what is called chipboard (or greyboard or plainboard) which is like the color of newspaper (there is also an option for colored chipboard that will give color to the inside of the box). Cutting and scoring dies are used to cut the chipboard to its correct shape and size, while the sides of the box are scored (not cut all the way through to facilitate folding).
The box sides are folded up at the score areas to complete the box form. Tape is then applied to secure or “stay” the sides using a machine called a quad stayer.
The wrap is prepared by having it printed-on (if desired) then trimmed or “mitered” to perfectly fit the box. The box is then placed on the wrap where glue is used to adhere the two together.
Wraps can be all types of paper or fabrics with a staggering array of textures and colors and finishes (i.e. high gloss or matte) including embossing, foil stamping and flocking (adding sparkles). Castle Pierce also offers many different kinds of custom box embellishments.
2-Piece Base & Lid Setup Box
Elevate your packaging with our elegant and versatile 2-piece setup boxes. Ideal for premium products, these boxes consist of a sturdy base and a snug-fitting lid, providing both protection and aesthetics. Whether you need a standard telescoping design, a partial telescoping option, or a unique shoebox style, our skilled team crafts each box to perfection.
Neck Box or Shouldered Box
A type of partial telescope box that includes a tray that is glued inside the base and protrudes up past the top of the base. This protrusion creates a “neck” and the top edge of the base becomes the “shoulder”. Sometimes the tray that creates the neck is glued to the inside of the lid instead of the base. Sometimes the “neck” is made extra long and it protrudes past the lip of the base so much so that it creates a gap between the lid and the base. This is done mostly for aesthetic reasons.
Hinged Lid Rigid Box or Cigar Box
For a touch of luxury, our hinged lid rigid boxes, also known as cigar boxes, offer an exquisite packaging solution. These boxes are crafted with precision, featuring a hinged lid that adds a sense of grandeur to your products. This is where the lid is attached permanently and stays closed using gravitational forces (free of cost) or with a magnetic strip or a ribbon binding (costs a little extra). These boxes are great for frequent-use products that are meant to be stored in their packaging in-between uses.
2-Piece Slip Case &
T-Style Slip Case
When it comes to versatility, our slip cases are unbeatable. Whether you opt for a 2-piece slip case or a T-style design, these cases are built with a 5-sided sleeve and a tray which slides into the sleeve. Different options of opening include thumb notch, paperboard or ribbon pull tabs.
Setup Box Inserts
Enhance organization and protection within your packaging using our setup box inserts. These inserts are designed to fit seamlessly within the box, keeping your products secure during transit and enhancing the unboxing experience.
in-house capabilities
in-house CAD capabilities
Our structural design lab boasts cutting-edge CAD capabilities. Our skilled designers translate your ideas into precise mock-ups and structural designs, ensuring that every detail of your packaging is perfected before production.
in-house die-cutting, folding & gluing
At our facility, we handle every step of the packaging process, including die-cutting, folding, and gluing. This end-to-end approach ensures quality control and faster lead times, setting us apart as a reliable partner for your packaging needs.
partner with Castle Pierce for your offset printing needs
Experience the difference of 5th generation family-owned knowledge and culture combined with our commitment to delivering fast lead times, niche-fit solutions, multi-medium packaging options, and unparalleled brand integrity. Contact us today to explore how our expertise can elevate your brand’s packaging to new heights.
explore our packaging products
The rigid box has so many variations that it would be nearly impossible to list them all; add on top of that a plethora of possible extras such as platforms, compartments, magnetic closures, windows, ribbon pulls, handles, etc. and we can build you the perfect packaging for your specific needs.
