Box Style

A guide to the box structures themselves. If you know what you are packing but not which format it should be, start here: each structural family is explained in plain terms, then pointed at the range that makes it. Orders start from 100 units.

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A box style, or dieline, is the flat shape a box is cut and creased from before it is folded. It decides how the box closes, how the base carries weight, and how it opens in front of whoever receives it. Two boxes can hold the same product, in the same board, printed the same way, and still behave completely differently because the dieline is different.

This page is a map, not a product range. It explains the structural families, says what each is genuinely good at, and then points you at the part of the catalogue that makes it. The structural explanations below are general packaging mechanics, true of these formats wherever they are made. Anything specific to what All Custom Packaging does is stated separately at the end.

What actually narrows the list

Most of the list rules itself out once two things are settled: how the box needs to close, and what its base has to carry. On closing, a tuck flap is quick and reversible, a glued seal end stays shut until it is opened, and a separate lid turns the opening into the moment. On the base, a folded tuck is fine for light contents and gives way under real weight, where a glued or locking base holds. Visibility is the third lever, and it changes the structure itself: a window, an open tray or a display cut is cut into the dieline, not added to the print.

Tuck-end cartons, the default folding carton

This is the format most people picture. A Straight Tuck End Boxes has both tuck flaps hinged from the back panel, so the front face stays unbroken for print. A Reverse Tuck End Boxes alternates them, which uses less board and is the cheaper cut. Variants add a locking flap or a dust flap for a firmer close. Where the front should show the product, a Straight Tuck With Customizable Window takes a die-cut aperture. If a printed retail carton is what you are after, that range is Custom Product Boxes.

Auto-bottom bases, for when there is weight

The base is where light cartons fail. An auto-bottom, sometimes called crash-lock, arrives with the base pre-glued so it snaps into shape as the box is opened out, and it holds far better under a filled load than a hand-folded tuck base. A Tuck End Auto Bottom pairs it with a tuck top, and a Full Flap Auto Bottom Boxes closes fully over the top. It also speeds up hand-packing, since there is no base to assemble. For heavier contents and transit, that thinking continues in Corrugated Boxes.

Seal-end, tear strips and dispensers

A Seal End is glued at both ends, so it is closed during production and opened once by the customer. It is the format used where the pack is not meant to be reclosed. A Seal End With Tear Open adds a perforated strip so it opens cleanly by hand. A Perforated Dispenser Box keeps part of the box intact, so stock can be taken out a few at a time on a counter.

Two-piece, lids and framed trays

Here the lid is a separate piece. A Two Piece Box is a base with a separate lift-off lid. A Roll Ends With Lid and a Triangular Tray Lid apply the same idea to rolled and angled shapes. When the box should feel substantial and the lift is part of the point, that is Rigid Boxes, and the cylindrical version of the same lidded idea sits in Round Boxes.

Open trays, and trays with a sleeve

A tray has no top at all. A Simplex Tray or a Four Corner Tray folds up from one piece with locking corners, which is why trays are quick to assemble and easy to fill in a line. The open top is the trade-off: it presents well and protects less. Sliding a printed band over it fixes that, which is the Double Glued Side Wall Tray And Sleeve idea, and that combination is covered by Sleeve Packaging. Trays are also the base format behind a lot of food packaging. Some of them hold food directly. Food-contact material suitability is confirmed for the specific material before production. The food range itself is Custom Food Boxes.

Display, counter and hanger formats

These are built to be seen on a shop floor. A Side Lock Tuck Top Display Box ships as a closed box and opens into a display, a POP Counter Display Tray sits by a till, and an Easel Display Stand props itself upright. Peg formats hang instead: a Five Panel Hanger or a Header Card puts the product on a hook with the branding above it. All of that belongs to Display Boxes.

Carriers, gable tops and handles

When the pack has to be picked up and walked with, the handle is designed into the dieline rather than added on. A Six Pack Bottle Carrier and a Wine Bottle Carriers combine dividers with a lifting point, and a Gable Box Auto Bottom folds to a peaked top with a cut-out handle. Choosing between them by what you are carrying and how many is what Carrier Packaging covers.

Shaped, specialist and everything else

Some dielines exist for a shape. A Pillow Box curves at both ends and is covered by Pillow Boxes; a Hexagon gives six faces to print on. Others exist for one job: a Mailer With Zipper is a postal format, covered by Custom Mailer Boxes, and a Punch Partition is the divider that goes inside another box, which is Custom Insert Boxes. Flat formats such as a Four Panel CD Jacket or a Document Folder fold flat instead of building into a box, and the printed folder range itself is Presentation Folders. A Self Lock Cake Box is the locking tray format used for cakes, and that range is Custom Cake Boxes.

What All Custom Packaging adds to any of these

Everything above is general packaging structure. What is specific here is that any of these formats is die-cut to your own product dimensions, in paperboard, kraft, corrugated or rigid board. There is no fixed size list to choose from. Printing covers anything from a single logo to artwork across every panel, using offset, digital or screen depending on the run. Pantone references and CMYK values can be used to manage colour consistency, subject to normal variation caused by the chosen board, ink, coating and production method. Lamination in matt or gloss, foil stamping, embossed or debossed detail and a spot-UV highlight are all offered, with availability set by the board, the style and the run. Orders start from 100 units. Standard production takes 6 to 8 business days after approval. Design support is free. A digital 3D mock-up is free. UK delivery is free. There are no setup fees.

Customer reviews

Customer Reviews

Real feedback from customers who trust us with their custom packaging.

Product FAQs

Frequently Asked Questions

Clear answers about ordering, artwork, production, materials and delivery.

Can you match a structure to a box I already use?

Yes. Send the box itself or its flat dimensions and we can identify the dieline it was cut from, then quote the same structure or suggest a closer one. That is usually quicker than picking a format from a list.

Does a stronger base cost more?

Yes. An auto-bottom carries a gluing stage that a hand-folded tuck base does not, so the unit cost is higher. It earns that back where the contents are heavy enough to need it, or where packing speed matters across a long run.

Can any structure be made in any material?

Not always. A deep tray or a heavy carrier needs a board with enough stiffness, and a fine shaped dieline creases better in a lighter board, so the structure and the material are chosen together. Tell us the format you are considering and we will confirm what it can be made in.

Can a structure be changed, for example adding a window or an insert?

Yes. Windows, apertures and fitted inserts are die-cut into or for a given format, so a standard carton can carry a window, and a tray or box can take a partition cut to the product.

What is the minimum order for a custom box style?

Orders start from 100 units. Standard production takes 6 to 8 business days after approval. UK delivery is free.

✦ Finishing Options

Finishing & Material Options

Choose from premium coating, board, printing and finishing options for your insert boxes.

Varnish

Varnish

A transparent finishing layer available in gloss, satin, or matte effects. It enhances the printed surface and adds an extra layer of visual appeal and light protection.

Spot UV

Spot UV

A UV-cured coating applied to specific areas of the design to create gloss or matte contrast and draw attention to important details.

Soft Touch Coating

Soft Touch Coating

A smooth, velvety coating that creates a soft tactile feel and gives packaging a refined luxury look. It improves the unboxing experience and supports a high-end product presentation.

Silk Lamination

Silk Lamination

A soft, smooth lamination with a refined satin-like finish. It gives packaging a premium feel while keeping the surface elegant, subtle, and easy to handle.

Spot Gloss UV

Spot Gloss UV

A high-gloss UV coating applied only to selected design areas to create sharp contrast, highlight logos, and add a premium visual effect without coating the whole surface.

Aqueous Coating

Aqueous Coating

A clear, fast-drying water-based coating that adds a smooth protective layer while maintaining a clean and professional surface finish. It is a practical choice for everyday printed packaging.

Anti-Scratch

Anti-Scratch

A durable protective film that helps reduce visible scratches, scuffs, fingerprints, and daily handling marks. It keeps packaging looking clean, polished, and premium for longer.

White Kraft Paper

White Kraft Paper

A bleached kraft paperboard made from a mix of virgin and recycled pulp, offering a clean white surface for crisp and polished packaging designs.

Uncoated Unbleached Kraft

Uncoated Unbleached Kraft

A natural kraft paperboard without coating, made from virgin and recycled pulp. It provides a raw, organic appearance with sturdy packaging strength.

SBS C2S Paper

SBS C2S Paper

A premium bleached paperboard coated on both sides, designed for excellent print quality, die-cutting, and professional packaging results.

SBS C1S Paper

SBS C1S Paper

A high-quality bleached paperboard coated on one side. It provides a clean printable face with a premium packaging feel.

Printing Paper

Printing Paper

A smooth printable paper stock that supports high-resolution graphics, clean text, and rich color output for refined packaging presentation.

Natural Brown Kraft Paper

Natural Brown Kraft Paper

A natural kraft paperboard made from strong virgin and recycled pulp. It provides an organic, earthy look for sustainable and simple packaging.

Metallic Paper

Metallic Paper

A specialty paperboard with a laminated metallic surface available in gold, silver, and other premium finishes for luxury visual impact.

Holographic Paper

Holographic Paper

A specialty paperboard with a laminated holographic surface that creates a reflective, rainbow-like appearance for eye-catching product packaging.

Fully Recycled CCNB Paper

Fully Recycled CCNB Paper

A recycled duplex paperboard with a white printable surface. It is ideal for economical packaging that still requires clean graphics and brand presentation.

Clay-Coated Kraft Back

Clay-Coated Kraft Back

A kraft board with a smooth clay-coated white face for quality printing and a natural kraft reverse side for a strong, authentic appearance.

Clay Natural Kraft

Clay Natural Kraft

A kraft paperboard with a clay-coated printable top surface and a natural unbleached kraft back. It balances clean branding with a rustic natural look.

CCNB Paper

CCNB Paper

A duplex paperboard made with recycled pulp and a coated white printable surface. It delivers smooth print results for affordable carton packaging.

Black Kraft Paper

Black Kraft Paper

A black-dyed kraft board with a natural paper texture and excellent strength. It creates a bold, premium look for luxury and specialty packaging.

Window Patching

Window Patching

A packaging technique where a die-cut opening is covered with a transparent film, allowing the product inside to remain visible while staying protected.

Registered Embossing

Registered Embossing

An embossing technique where the raised design is precisely aligned with printed artwork to improve detail, texture, and overall presentation.

Hot Foil Stamping

Hot Foil Stamping

A finishing process in which heat and pressure transfer metallic foil to the surface, creating a premium, shiny, and luxurious effect.

Combination Embossing

Combination Embossing

A premium finishing method that combines embossing with foil stamping to create a raised design with metallic color and strong visual impact.

Cold Foil Stamping

Cold Foil Stamping

A decorative process that transfers foil onto selected areas of the surface using UV-curable adhesive, creating a bright metallic effect with sharp detail.

Blind Embossing

Blind Embossing

A technique that raises a design from the surface without ink or foil, giving packaging a clean, elegant, and textured appearance.

Blind Debossing

Blind Debossing

A finishing technique that presses a design into the material to create a recessed impression without using ink or foil. It adds subtle depth and a refined tactile effect.

UV Printing

UV Printing

A fast-curing printing process that uses ultraviolet light to dry ink instantly, delivering sharp detail, vibrant colors, and a premium finish.

Screen Printing

Screen Printing

A durable printing method that uses a mesh screen and stencil to apply ink to surfaces. It is ideal for bold colors and high-impact packaging designs.

Offset Printing

Offset Printing

A traditional high-quality printing process that transfers designs from plates to a rubber blanket before printing, making it ideal for large-volume production.

Digital Printing

Digital Printing

A modern printing method that does not require printing plates, making it cost-effective and efficient for short runs, sample production, and small-batch quantities.

Triple Wall Flute

Triple Wall Flute

Built with three corrugated layers between four linerboard sheets, providing heavy-duty strength for large or industrial packaging needs.

Single Wall Flute

Single Wall Flute

A standard corrugated structure with one fluted medium and two linerboards, providing dependable strength for everyday packaging.

Single Flute

Single Flute

A corrugated sheet with one flute layer between two liners, offering lightweight strength for protective packaging.

F-Flute

F-Flute

An ultra-thin flute grade designed for lightweight packaging, small retail boxes, and high-quality printed presentation.

E-Flute

E-Flute

A slim flute grade with a flatter surface, ideal for detailed printing, display packaging, and premium retail boxes.

Double Wall Flute

Double Wall Flute

Made with two layers of corrugated medium between linerboard sheets, offering added strength and durability for heavier products.

C-Flute

C-Flute

A versatile corrugated flute that offers balanced compression strength, cushioning, and printability for many packaging applications.

B-Flute

B-Flute

A thinner flute grade with a smooth surface, making it suitable for high-quality printing, precise die-cutting, and neat retail packaging.

A-Flute

A-Flute

A thick corrugated flute profile that provides excellent cushioning, compression strength, and stacking support for protective packaging.

Oyster White Board

Oyster White Board

A coated linerboard with an off-white surface, suitable for high-quality printing and a refined packaging appearance.

Natural Kraft Board

Natural Kraft Board

An unbleached kraft linerboard made from recycled paper pulp, offering a natural look with strong durability for eco-conscious packaging.

Kemi White Board

Kemi White Board

A coated semi-gloss linerboard with a smooth white surface, ideal for sharp printing, premium presentation, and retail-ready packaging.

Bleached White Board

Bleached White Board

A fully bleached corrugated board with a bright white surface, designed to produce clean, vibrant, and high-quality printed packaging.

UV Ink

UV Ink

A UV-cured ink that dries instantly under ultraviolet light and creates crisp, high-quality print results on a wide range of packaging materials.

Soy Ink

Soy Ink

A plant-based ink made with soybean oil, offering rich color output and a more sustainable printing option for carton packaging.

Pantone

Pantone

A standardized color-matching system used to achieve consistent, accurate brand colors across packaging, labels, and printed materials.

CMYK

CMYK

A full-color printing process using cyan, magenta, yellow, and black inks to create vibrant images, gradients, and detailed packaging artwork.