About one in six orders we ship is fully custom. The reclaimed pile is broad but it isn't infinite, and there are applications where a brand-new, dimensionally-perfect box is the right answer. We'd rather build it ourselves than ship the wrong thing.
What we'll build.
- Any footprint between 24 × 24 and 60 × 60.
- Heights from 12" up to 60".
- Single-wall through five-wall corrugate.
- ECT ratings from 32 to 1,500.
- Die-cuts: hand holes, pour spouts, drain holes, custom flap geometries.
- Print: 1- and 2-color flexo direct on the corrugate.
- Coatings: wax, moisture-resistant, FDA-compliant.
Typical lead times.
| Run size | Standard wall | Custom die-cut |
|---|---|---|
| 1 – 50 | 3 – 5 business days | 5 – 7 business days |
| 51 – 500 | 5 – 8 business days | 7 – 10 business days |
| 500 – 5,000 | 8 – 12 business days | 10 – 15 business days |
| 5,000+ | Quote by job | Quote by job |
The hand-off.
Custom orders go through three quick checkpoints: spec confirmation, sample (we'll send one before a big run), and production. We share a digital proof at every step. No ghost-and-ship.
When custom is the right call.
About one in six orders we ship is fully custom. The reasons customers commit to custom rather than work from reclaimed inventory cluster into five buckets.
- The footprint or height doesn't exist on the floor. Most common reason. Unusual dimensions for unusual equipment, automation cell sizes, or unique product geometry.
- Branded print is required. Reclaimed boxes have their previous print history. Custom builds let you control 1- or 2-color flexo direct on the corrugate.
- Spec is so heavy that no reclaimed wall count matches. Quad- and five-wall builds for 3,000+ lb loads.
- Die-cuts are needed. Pour spouts, drain holes, hand cut-outs, custom flap geometries — these require a print plate and die. Custom build only.
- The customer requires new corrugate by spec. Some receivers contractually require new packaging. Custom build is the path.
Print specifications.
For customers wanting branded corrugate, here's the print envelope.
- 1- or 2-color flexo direct-print on the corrugate at our supplier's converter facility.
- Print area typically limited to the four side walls; not the top or bottom flaps.
- Color matching: standard Pantone book; non-standard colors quoted custom.
- Plate cost: one-time setup fee per design; runs from $200 to $850 depending on plate count and complexity.
- Lead time: add 3–5 business days to the standard build for print plates and color match.
Coatings and treatments.
Beyond standard kraft corrugate, we can spec several coating and treatment options. Each comes with cost and lead-time implications.
| Treatment | What it does | Common use |
|---|---|---|
| Wax coating | Wet-strength resistance | Produce, dairy, chilled goods |
| Polycoat (PE film) | Moisture barrier, recyclable in OCC stream (unlike wax) | Moderate moisture environments |
| Anti-static treatment | ESD protection | Electronics components |
| FDA-compliant adhesives | Food contact safety | Direct food packaging |
| Fire-retardant | Surface ignition resistance | Specialty industrial |
The proof process.
Before any large custom run, we send proofs. Three steps.
- CAD proof. A 2D layout drawing showing all dimensions, die-cuts, and print placement. Sent within 1–2 days of spec sign-off.
- Physical sample. For orders of 200+ units, we ship a single complete unit for fit-test. Sample lead time 5–8 business days.
- Pre-production approval. Customer signs off in writing before production begins.
No production starts without explicit sign-off. This adds 1–2 days to lead time but eliminates the much more costly outcome of producing 5,000 boxes against a misunderstood spec.
Minimum order quantities.
| Build type | Minimum order | Lead time |
|---|---|---|
| Standard wall, no print, no die-cut | 1 unit (sample) | 3–5 days |
| Standard wall, 1-color print | 100 units | 7–10 days |
| Standard wall, 2-color print | 250 units | 10–15 days |
| Custom die-cut | 50 units | 7–10 days |
| Treated / coated | 250 units | 10–15 days |
| Print + die-cut + coated | 500 units | 15–20 days |
Frequently asked.
Can I get a sample of a custom design before committing?
Yes. For orders over 200 units we always send one physical sample. For smaller orders we proceed to production after CAD proof sign-off.
What's the smallest custom run you can do?
A single unit. The economics get unfavorable below 50 units because the setup costs (CAD, plate if printed, die if cut) get amortized across very few boxes. We'll quote regardless.
Can you handle full color (4-color process) print?
Limited. Standard corrugate flexo isn't great for 4-color. For high-fidelity print we partner with a specialty converter; lead times extend significantly.