packaging

      How to Choose the Right Case Box Supplier for Your CPG Product

      Case boxes are a key part of getting your product retail-ready and distribution-ready. They protect your individual units during transportation, help distributors manage your inventory, and ensure your product reaches stores with the longest shelf life possible.

      Every distributor has clear requirements for how they want product packed, labeled, palletized, and delivered. Choosing the right case-box approach early on makes your launch smoother and keeps your cost structure in check.

      1. Start Simple: Generic Boxes 

      In the beginning, the most cost-effective and flexible approach is to work with a broadline packaging supplier. These companies stock standard-sized case boxes, offer low minimums, and can ship quickly.

      When you’re first launching, your packaging and SKUs may still change. Using a generic box and applying a weatherized label is the most affordable, lowest-risk option.

      Why this works well for new CPG brands:

      • Lower upfront cost

      • Faster lead times

      • Easy to update if you adjust your formulation, SKU, or case count

      • No need to inventory multiple box versions

      • Distributors still get the clear labeling they need

      Weatherized Labels - Print Yourself

      Weatherized labels are printed stickers applied to unprinted case boxes. These labels hold up well in warehouses, on pallets, and in trucks as long as they are weatherized. 

      • Recurring cost: Each label costs money to print but this is usually negligible ( a few cents), especially if you purchase a thermal printer.

      • Flexibility: Easy to update if your SKU changes or you need to correct information. 

      • Inventory benefit: You can keep one generic case box on hand and apply labels as needed.

      • Ideal for: Early-stage brands that expect packaging or formulation changes.

      Phase Two (Optional): The Hybrid Approach

      Some brands reach a point where their SKUs are stable enough to justify a custom-sized case box, but they still want the flexibility of weatherized labels. This creates a smart middle path between launch and full pre-printed packaging.

      The Hybrid Option: Custom Box + Weatherized Label

      With this approach, you:

      1. Work with a corrugated box manufacturer to get a custom-sized, unprinted case box that fits your product perfectly

      2. Continue applying weatherized labels instead of pre-printing the box

      Why the Hybrid Approach Works

      • Better product protection from a perfectly sized box

      • Lower damage rates in distribution

      • No printing setup costs

      • Ability to update info quickly (great for new SKUs or frequent changes)

      • Simplified inventory (still only one base box + labels)

      • Lower risk while maintaining operational improvement

      This is often the right choice for brands selling into 50–150 stores or expanding from local to regional distribution.

      3. Grow Into Custom Case Boxes

      Once you find product market fit, with recurring and increasing orders, it often makes sense to shift to a custom, pre-printed corrugated case box. 

      A custom box is sized precisely for your product, reduces shipping damage, and can be printed with everything distributors want: SKU number, barcode, product name, flavor, unit count, and handling instructions.

      Why Custom Boxes Make Sense at Scale

      • Better product protection during freight and warehouse handling

      • Cleaner, faster receiving for distributors

      • Lower per-unit cost once you’re ordering larger quantities

      • More efficient palletization and fewer damages

      Who Makes Custom Case Boxes?

      Broadline suppliers do not typically manufacture custom corrugated boxes. For this type of packaging, you’ll need to work with a corrugated box manufacturer.

      Corrugated manufacturers can provide:

      • Custom sizes tailored to your unit packaging

      • Pre-printed case artwork

      • Multiple board grades

      • Volume pricing

      • Consistent lead times

      This shift typically happens as brands move deeper into retail distribution and begin sending more product through warehouses.

      The Right Case Box Strategy Helps You Scale

      A phased approach to case boxes keeps your early costs low, improves reliability as you grow, and builds the operational strength needed for regional and national scale.

      Start with generic boxes.
      Move to hybrid when you need better fit and flexibility.
      Shift to fully custom when your volume supports it.

      This progression supports better margins, fewer mistakes, stronger defensibility, and smoother U.S. market entry.

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