custom rigid box packaging
rigid setup box services
Custom rigid boxes, also known as rigid setup boxes, are a premium packaging solution designed to elevate your products with strength and style.
These boxes are four times thicker than standard folding cartons, ensuring exceptional durability and protection. Instead of direct printing, they are wrapped with high-quality paper, providing customized design opportunities and vibrant branding.
Rigid box packaging is a popular choice for products across industries, including luxury cosmetics and premium spirits. From custom-printed rigid boxes to eco-friendly options, businesses can select the best packaging options to suit their needs.
Why Choose Standard Rigid Boxes for Your Business
Rigid box packaging provides a high-end look and superior protection, making it an excellent choice for shipping and retail display. Whether you need gift boxes for an enhanced unboxing experience or sturdy packaging solutions for high-end products, rigid boxes offer the highest quality.
Cost Effective
Compared to tins and other packaging options, standard rigid boxes are affordable without compromising durability or appearance.
Durable
Rigid setup boxes offer exceptional durability for shipping, retail, and long-term storage.
Aesthetic Appeal
The luxury look and customization opportunities provide an elevated retail and unboxing experience that enhances customer perception.
Keep Products Secure
Custom inserts for foam, cardboard, or molded fit help keep products in place.
Sustainable
There are eco-friendly options available to support your company’s sustainability initiatives.
How Are Rigid Setup Boxes Made?
Custom rigid box packaging begins with chipboard, also known as greyboard or plainboard, which is cut and scored into precise shapes. The structure is assembled using quad stayer machines for clean, secure folds.
The outer wrap, made from luxury materials with custom printing options, is carefully applied to the box. You can choose from finishes such as embossing, foil stamping, high gloss, or matte for a customized design that enhances the luxury product experience.
Our Rigid Box Style Options
Two-Piece Base & Lid Setup Box
For a classic and timeless look, our two-piece base and lid setup boxes provide an excellent packaging solution. These rigid setup boxes are ideal for high-end products and can be customized to fit different order quantities. Options include standard telescoping, partial telescoping, and shoebox-style designs.
Neck Box or Shouldered Box
Neck boxes feature an internal tray that creates a “neck” and “shoulder” effect. This sophisticated style is perfect for products requiring additional reinforcement and elegant presentation.
Hinged Lid Rigid Box or Cigar Box
Our hinged-lid rigid boxes, also known as cigar boxes, offer a premium unboxing experience. They feature a permanently attached lid that can be secured with a ribbon ties or tuck closures. These custom rigid boxes are an excellent choice for frequent-use products and luxury packaging.
Two-Piece Slip Case &
T-Style Slip Case
Slip cases offer sleek and functional packaging options. Available in both two-piece and T-style designs, these rigid boxes feature a five-sided sleeve and a tray that slides in and out. Features such as thumb notches, ribbon pulls, and paperboard tabs provide added convenience and appeal.
Custom Rigid Box Inserts
Enhance your custom box with box inserts that provide additional protection and organization. Whether you need foam, cardboard, or molded inserts, our solutions help secure your products while elevating the unboxing experience.
Rigid Boxes vs. Tin Packaging vs. Folding Cartons
Compare cost, durability, sustainability, and more at a glance.
| Feature / Factor | Rigid Boxes | Tin Packaging | Folding Cartons |
|---|---|---|---|
| Cost | Moderate. Balances cost with durability and aesthetic appeal. | High. Costly to produce and ship. | Low. Cost-effective for basic packaging. |
| Durability | Very strong. Protects products during shipping and retail handling. | Very strong. Dent-resistant but heavy. | Moderate. Suitable for lightweight products. |
| Brand Perception | Premium, luxury feel that elevates the retail and unboxing experience. | Premium look but often associated with food and limited industries. | Can be elevated with design but less associated with “luxury.” |
| Eco-Friendly Options | Yes. Recyclable chipboard and paper wraps available. | Limited. Harder to recycle and requires energy-intensive production and transport. | Yes. Recyclable and often made from renewable sources. |
| Weight | Lightweight compared to tins and sturdy enough for premium products. | Heavy. Increases shipping costs and handling challenges. | Lightweight and easy to ship. |
| Lead Times | Fast. Widely available, quick turnaround. | Longer. Overseas manufacturing is common, making delays more likely. | Fast. Widely available, quick turnaround. |
| Industry Use Cases | Luxury goods, cosmetics, electronics, spirits, gift packaging. | Specialty foods, candies, limited premium markets. | Everyday consumer goods, retail, fast-moving products. |
in-house capabilities
in-house CAD capabilities
Our structural design lab boasts cutting-edge CAD capabilities to turn your ideas into accurate mock-ups and production-ready designs. Our skilled designers will ensure 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 packaging solutions
With generations of printing and packaging expertise, Castle Pierce is your trusted partner for custom rigid box packaging.
As a U.S. packaging company, Castle Pierce provides stronger relationships, clearer communication, and faster lead times than overseas sourcing. Local support means design changes, troubleshooting, and scaling can happen quickly and efficiently.
Whether you’re launching a new product or upgrading your brand packaging, our standard rigid boxes provide the quality, reliability, and service you need to succeed.
Custom Rigid Box FAQs
Are Rigid Boxes Eco-Friendly?
Yes! We offer recyclable, reusable, and eco-conscious material options. Working with a U.S. packaging company also reduces overall environmental impact compared to overseas suppliers.
How Do Rigid Boxes Compare To Tin Packaging?
Rigid boxes are more cost-effective, lighter, and easier to customize, while still offering strength and a premium feel. With the majority of tin being imported, rigid boxes can reduce the impact of tariffs and supply chain issues.
Can Rigid Boxes Be Customized For Unique Products?
Absolutely. With a variety of styles, finishes, and inserts, rigid boxes are designed to fit your product perfectly and show off your brand.
explore our custom packaging products
Discover endless possibilities with our custom packaging solutions. From a variety of rigid box styles to premium add-ons like ribbon pulls, windows, and compartments, we can create the perfect packaging tailored to your needs.