A quick query for you. Packaging of your iPad or your favorite lip balm bought online, which one do you like better? Well, if you’re thinking of the former one, you’re not alone!
We think exactly the same way.
Why? Because the gadget is expensive and needs to be delivered with proper care. Also, only some people can get it, so the buyers must be given fancier treatment.
The packaging of a product can deliver a premium feel. This premium-ness is what custom rigid boxes provide. They take the product inside to a whole new level.
Besides giving a premium appearance, there’s a lot of reasons why these boxes are more expensive than custom mailer boxes.
So, let’s explore each one of these reasons together, shall we?
What are Custom Rigid Boxes?
Custom rigid boxes are also known as setup boxes. They are popular because of their sturdy, inflexible material and structure.
Most importantly, unlike other boxes, they don’t fold flat except if they are collapsible boxes. This toughness is what sets them apart.
Their rigidity gives them a substantial, high-end feel that elevates any product they encase with refinement and elegance.
Typically, these types of custom boxes are made of high-density paperboard, much thicker than the cardboard used in standard shipping boxes.
Packaging companies often use decorative paper, cloth, and custom finishes to improve the appearance and longevity of these custom boxes.
What are Custom Mailer Boxes?
These boxes, made of corrugated paper, offer two things: efficiency and practicality. Their purpose is to keep goods safe during transportation while maintaining affordability and user-friendliness.
Because of their adaptability, companies of all kinds, from little startups to massive e-commerce giants, love them.
These boxes provide a dependable solution that guarantees your products arrive safely regardless of how many parcels you’re shipping—from a single item to thousands.
Reasons Why Custom Rigid Boxes are More Expensive
So, it’s not just about the premium feel and appearance of these two custom boxes, there are actual reasons behind the more expensive per unit price of one.
Material
First and foremost, the base materials of the rigid boxes are different from those used for mailer boxes.
To hold true to their name and need, rigid boxes need to be thicker and studier in nature compared to mailer boxes. For this reason, they are constructed using high-density paperboard as opposed to corrugated cardboard.
This thickness of paperboard makes them pretty solid and durable. This enables the boxes to keep the delicate items inside safe during transit.
The solid base is also layered with high-quality art paper to achieve the desired print result. This specialty paper is also a more expensive alternative to those used to construct the walls of the corrugated cardboard sheet for the mailer box.
Manufacturing Process
After the materials are the differences in the manufacturing process of the two boxes. The printing and cutting of mailer boxes are a much more automated process.
Let’s get to those steps briefly:
- Cutting and Scoring
First off, high-quality thick paperboard is cut and scored into specific shapes and sizes.
- Assembly
The pre-cut and pressured pieces are assembled by hand to achieve the desired shape and size of each box. This means that each of the custom rigid boxes is handmade thereby increasing the cost of labor in the process.
- Wrapping
Next, the printed specialty paper is overlain on the assembled base. This step requires the utmost care and skill to ensure that no wrinkles and bubbles are left on the surface.
This also required laborers to do the hand work, again adding to the cost of the custom boxes.
- Final Touches
Further required details, such as ribbons or bows, custom sleeves, magnetic closure, or any custom box inserts are added along the process.
All of these steps need dedicated time and skill and often specialized machinery, which contributes to a higher price tag for custom rigid boxes.
Quality Control Check
Since rigid boxes are typically used for luxury and high-end products, they undergo strict quality control checks.
Every box is checked based on specific standards to make sure the built quality and structure are perfect.
This is done both manually and through machines. The more effort and time put into the inspection, the higher the cost will be!
Low Production Volumes
Another important factor of why custom rigid boxes are more expensive than custom mailer boxes is that they are usually manufactured in smaller quantities.
Deluxe brands might order smaller runs of such boxes for limited editions or luxury collections which reduces the economies of scale per production cycle.
It increases the cost of making per box compared to making them in bulk all because fixed costs (for instance, setup and design) are spread over only a few boxes.
Customization, Design, and Fulfillment
All customized boxes are personalized to reflect the identity of the brand and make the unboxing experience better for the customer. Marketing teams together with their custom packaging partners team spend hours consulting on design ideas before the custom boxes are “okayed” for manufacturing.
This consultation process when developing custom rigid boxes is typically more thorough and time-consuming. Even though rigid boxes are indispensable when it comes to delivering a more premium feel to the end consumer, they do come with their limitations.
Standard rigid boxes, such as the two-piece rigid box or the hinged-neck rigid box need to be stored and shipped as it. This puts significant pressure on logistics and warehouse services and, therefore, is something that the marketing teams need to consider carefully.
Not only the greater number of consultation hours with the vendors but also the shipping and storing of the rigid box adds to its cost.
But as noted before, the brand image and custom impact the rigid box delivers is worth the higher price tag.
Benefits and Trade-Offs
In all honesty, it’s pretty unfair to compare rigid and mailer boxes. Because it’s like comparing a luxury SUV with a budget car.
Both have their pros and cons and serve the specific need-states of consumers. For example, it would be quite disappointing to receive your top-of-the-range Louis Vuitton bag in a corrugated cardboard box, wouldn’t it?
Such decisions of mailer boxes vs rigid boxes are more applicable to mid-tier organizations who are considering running a promotional PR campaign or developing custom packaging for their new higher-end product. This category in fact makes up most of the businesses around the world, therefore making the comparison unfair but relevant.
So after looking at the factors adding to the cost differentials of the two types of boxes, let’s dig into the pros and cons of each.
Figure 1: Comparison of Rigid Boxes vs Mailer Boxes
Pros of a Rigid Box over a Mailer Box
Reliability
Think of these boxes as tanks that survive bumps, jolts, drops, and weights while keeping the inside item safe and sound. Yes, they are this durable!
This is what makes them stand out and an undoubtedly clear choice for high-value items as they need extra protection.
A mailer box on the other hand gives a decent level of protection, especially depending on the flute construction of its walls, but it’s definitely not the same as that of the rigid box.
To enhance the protection of fragile items being packed in a mailer box, additional inserts and inlays would need to be used.
Premium Look
Undeniably, these custom boxes are one of the most beautiful packaging solutions available. They look and feel luxurious, and add directly to the value of the item inside even more.
Better Customer Experience
High-end brands like Apple and Channel choose these boxes since they believe in delivering customer experience rather than simply a product.
The very first sight of their package gives the customers happiness and makes unboxing an event.
Limitations of a Rigid Box over a Mailer Box
Expensive
The high-quality materials and complicated production steps make a rigid box costly.
Also, these are made in small amounts which is a huge investment for companies, specifically startups, homes, and small businesses.
A mailer box is a pocket-friendly option. Crafted from corrugated cardboard, it is cheaper to make and is shipped in bulk. The businesses that want to cut down their packaging costs mostly opt for these.
Shipping & Storage
Since you can ship and store a mailer box flat, it takes relatively less space than a rigid box.
This compactness is valuable for small businesses having small storage space.
Besides, it makes handling and shipping more efficient because you can move a large quantity of boxes in a smaller area.
Heavy Weight
The shipping cost of a rigid box is also higher because of its weight since it’s heavier.
The shipper has to pay quite some bucks for the shipment, especially if he’s shipping a large quantity.
Mailer boxes are lightweight, these boxes have low shipping costs. These are easier to handle and transport, making the logistics side of things a lot simpler.
Design Versatility
These boxes have so much design versatility that sometimes even the manufacturing team gets confused about what’s better and what’s not.
They can be made into multiple shapes and sizes to accommodate different products, ranging from jewelry pieces to large gadgets.
This gives a unique and perfect packaging solution to fit your product, making sure it’s well-protected and presented in the best possible way.
The Bottom Line
You can be spoilt for choice when choosing custom packaging with an established custom packaging manufacturer such as The Mailer Box. However, the specific choice between a rigid box and a mailer box depends on the brand’s preference and the value of the item packed inside.
A rigid box is simply a higher-end. It is made of more expensive materials and requires a lengthier and more labor-intensive manufacturing process.
Mailer boxes on the other hand are kings of the fast-moving e-commerce industry. Their benefit is precisely in being lightweight, easily foldable at packing points, and easily recyclable. They come with huge cost-saving advantages and are a perfect option for small businesses and startups.
