Leading the Pack: How Corrugated Box Manufacturers Are Shaping the Future of Packaging

Corrugated packaging is made from layers of paperboard glued together with a corrugated or wavy inner layer. Its design provides strength and durability, making it suitable for protecting products during storage and shipping. Due to its lightweight nature and recyclability, corrugated materials are commonly used for shipping boxes, retail displays, and product packaging.

This article will examine how corrugated box manufacturers produce versatile packaging solutions that meet various needs across industries.

Key Roles of Corrugated Box Manufacturers in the Packaging Industry

Below, we explore the aspects that make corrugated box manufacturers integral contributors to the packaging industry:

Design and Engineering

Packaging manufacturers are crucial in designing and engineering solutions tailored to their clients’ needs. They assess product fragility, weight, dimensions, and shipping requirements to create packaging that offers optimal protection and functionality. They also utilize computer-aided design (CAD) software and structural analysis tools to develop precise designs.

Material Sourcing and Innovation

The manufacturers are responsible for sourcing high-quality raw materials such as paperboard and adhesives to ensure the boxes’ durability and strength. They also contribute to innovation by researching and developing new materials, designs, and manufacturing methods to improve packaging performance and sustainability.

Customization and Printing

Corrugated box manufacturers provide customization options, allowing businesses to personalize their packaging with logos, product information, and images. They use modern printing processes such as flexography and digital printing to create high-quality designs on corrugated surfaces. This improves brand visibility and consumer appeal, leading to higher recognition and brand loyalty.

Supply Chain Management

Efficient supply chain management allows packaging manufacturers to meet client demands and ensure timely delivery of requested materials. They often coordinate with suppliers, logistics providers, and distribution networks to streamline production processes. This significantly contributes to improved customer satisfaction through on-time delivery and reliable order fulfillment.

Environmental Sustainability

Many box manufacturers prioritize environmental sustainability by using biodegradable, recyclable, and renewable materials in their packaging products. They follow environmentally friendly manufacturing procedures like waste minimization, energy efficiency, and water conservation. These measures reduce their environmental impact and promote sustainable packaging initiatives.

Emerging Trends and Technologies in Corrugated Packaging

The following trends are reshaping the corrugated packaging industry, driving innovation, sustainability, and efficiency:

Digital Printing

Digital printing technologies revolutionize corrugated packaging by offering high-quality, cost-effective, and customizable design solutions. This allows for shorter print runs, faster turnaround times, and the incorporation of variable data and designs.

E-Commerce Packaging Solutions

With the rapid growth of e-commerce, there is a growing demand for packaging solutions optimized for online retail environments. In response, corrugated packaging manufacturers are developing innovative designs like easy-open tear-strips, integrated handles, and custom-sized boxes.

Smart Packaging

Integrating RFID tags, QR codes, and sensors into corrugated packaging improves supply chain visibility, tracking, and authentication. Smart packaging systems provide real-time information on product location, condition, and consumption, which reduces waste and improves inventory management.

Sustainable Materials

The increasing focus on environmental sustainability drives the adoption of eco-friendly materials in corrugated packaging. This includes the use of recycled fibers and alternative materials such as bamboo and bagasse. Manufacturers are also exploring bio-based adhesives and coatings to reduce the environmental impact of packaging.

Choose Deluxe Packaging for Your Corrugated Packaging Needs

At Deluxe Packaging, we offer a comprehensive range of corrugated packaging solutions tailored to meet your specific needs. Our state-of-the-art manufacturing facilities and cutting-edge technology enable us to produce high-quality boxes with precision and efficiency. Whether you require standard shipping boxes or custom-designed retail displays, we have the expertise and capabilities to deliver innovative solutions!

Contact us or request a quote to get started.

Folding Carton Packaging: The Art and Science of First Impressions in Retail

As businesses seek ways to stand out in the crowded market, innovative packaging is gaining popularity as a cost-effective way to capitalize on market demand. As a result, sturdy paperboard folding cartons are becoming a go-to choice. They are eco-friendly and customizable, helping brands show their uniqueness while championing sustainability.

This article delves into how folding carton packaging design balances visual attractiveness and functionality, covering material selections, printing methods, and structural innovations.

Aesthetics and Functionality: The Heart of Carton Design

The following design elements define the visual and practical benefits of folding cartons:

Shape and Size Considerations

Whether delicately housing glassware or optimizing space for multiple items, tailoring the dimensions of folding cartons to suit specific product requirements is crucial. Accurate sizing and shaping ensure product protection and enhance efficiency in packaging and transportation operations, reflecting a commitment to quality and precision.

Structural Elements

From panels to flaps, folding carton packaging comprises various structural components that determine both form and function. For instance, thicker designs offer more robust protection for products. On the other hand, flexible patterns are more easily formed into intricate package designs and can house smaller goods.

Graphic Design and Branding

Crafting a visual identity that resonates with consumers is pivotal. Every design choice, from luxurious finishes to minimalist aesthetics, influences brand perception and consumer engagement. Striking a balance between aesthetics and functionality is essential to creating packaging that grabs attention and enhances the overall brand experience.

Printing Techniques for Folding Cartons

The following printing techniques enhance folding carton packaging, providing methods for achieving desired outcomes:

  • Offset printing:  This leverages rotating cylinders to facilitate rapid production and ensure consistency and efficiency in large-scale orders.
  • Digital printing: This embraces cutting-edge technology to create premium-quality outcomes with minimal setup, catering to smaller runs and dynamic design needs.
  • Flexography: Particularly suited for non-porous materials, flexographic printing delivers precise results, making it a favored choice for intricate folding carton labels.

Finishes and Effects

Once the foundation is laid, the following finishing touches can elevate folding cartons from functional to exceptional:

  • Embossing and debossing: Adding texture and depth, embossed or debossed elements enhance visual appeal and reinforce brand identity.
  • Foil stamping: Foil stamps infuse a touch of luxury to captivate attention with their gleaming accents and showcase key design elements.
  • Spot UV coating: From glossy highlights to matte textures, spot UV coating emphasizes specific areas, adding sophistication and tactile allure.
  • Varnishes and laminates: Varnishes and laminates enhance durability and vibrancy and ensure packages’ longevity and visual impact.
  • Die-cutting: Die-cutting shapes and molds the packaging with accuracy, ensuring that every detail aligns perfectly with the original vision.

Benefits of Folding Carton Packaging

Detailed below are the advantages of using folding carton packaging:

Versatility in Customization

Folding cartons can be tailored or adapted to fit different products and branding styles. They cater to a wide range of applications, from luxury cosmetic packaging with special coatings to vibrant, attention-grabbing food boxes.

Eco-Friendly Characteristics

Folding carton packaging is environmentally friendly and aligns with the growing demand for sustainable packaging solutions. Despite durability concerns, these cartons boast robustness and minimize waste by being constructed from a single sheet, striking a balance between eco-friendliness and product integrity.


Paperboard in folding carton packaging presents a cost-effective alternative to glass or metal options. This allows businesses to achieve quality packaging solutions without exceeding their budgetary constraints. Moreover, streamlined production processes enable the cost-effective manufacturing of large cartons, making them an ideal choice for companies seeking to optimize expenses.

Space-Efficient Design

Folding cartons are lightweight and designed to save space. This makes them perfect for shipping; they can carry a variety of products without taking up too much room. They also stack up neatly, especially with reverse-tuck folding carton boxes, letting businesses fit more in each shipment.

Elevate Your Brand With Deluxe Packaging!

At Deluxe Packaging, we excel in creating impactful folding carton packaging. With over 40 years of experience, we offer cost-effective, eco-friendly solutions tailored to your needs. We are committed to sustainability, with 100% recyclable materials showcasing responsible leadership while meeting environmental goals.

Contact us for tailored solutions and a quote!

Innovative Design in Custom Corrugated Packaging

The corrugated packaging industry has transformed due to the advancements in manufacturing technology and materials. Innovations like digital printing have allowed for more intricate designs that meet the diverse needs of businesses and consumers. These trends have propelled the industry forward, driving efficiency, flexibility, and sustainability in packaging solutions.

Join us in exploring the key design aspects of custom corrugated packaging!

Key Innovations in Designing Corrugated Packaging

The following innovations contribute to the evolution of custom corrugated packaging, offering enhanced functionality in meeting the diverse needs of industries:

Anti-Counterfeiting Features

Corrugated packaging designers are integrating sophisticated anti-counterfeiting features in response to the increasing threat of imitation products. These may include holographic components that are difficult to replicate and tamper-evident seals that provide visible evidence of tampering. Another example is unique identifiers like QR codes and serial numbers that can be scanned for authentication.

Barrier Coatings and Films

Barrier coatings and films are applied to custom corrugated packaging designs to further shield against moisture, gases, and odors. These materials are customizable to meet specific product protection requirements, such as preventing flavor transfer in food packaging and improving the shelf life of perishables.

Digital Printing

Digital printing technology allows high-quality graphics to be printed onto packaging materials. This innovation offers greater flexibility for customization, enabling businesses to create unique designs and branding elements tailored to their products and target markets. Moreover, it facilitates shorter production runs and faster turnaround times, ideal for on-demand or limited-edition packaging needs.

Easy-Open and Reclose Features

Corrugated packaging designers are focusing on developing easy-to-open and recloseable packaging solutions. These may include tear strips that facilitate effortless opening and resealable adhesives that securely close the package after use. This approach makes it easier for customers to access and enjoy the products while preserving freshness and convenience for multiple uses.

Interactive Packaging

With the rise of digital technology, corrugated packaging is becoming more interactive and engaging. Brands are leveraging augmented reality (AR) experiences, interactive games, and puzzles embedded within packaging designs to captivate consumers’ attention. These elements also provide valuable product information, promotions, and immersive brand experiences.

Multifunctional Packaging Design

Multifunctional packaging design integrates multiple features or functionalities into a single packaging solution, serving diverse purposes beyond containment and protection. Examples include packaging that doubles as a serving tray, storage container, or display stand. These enhance convenience, usability, and value-added benefits for consumers.

Structural Design Optimization

Advancements in structural design software have enabled the creation of innovative packaging shapes and configurations that maximize strength while minimizing material usage. Designers and manufacturers can reduce material waste, lower production costs, and improve product protection with optimized structural designs. Additionally, they can enhance shelf presence and consumer engagement.

Sustainable Packaging Solutions

Integrating sustainable design principles has driven the development of corrugated packaging solutions prioritizing recyclability and overall environmental responsibility. Manufacturers are increasingly utilizing recycled and renewable materials in corrugated packaging production, reducing the industry’s carbon footprint and reliance on finite resources.

Transit Packaging Optimization

Optimizing transit packaging focuses on designing solutions that minimize material usage, reduce package size and weight, and maximize space utilization. By enhancing packaging dimensions, stacking configurations, and load stability, brands can lower shipping costs, reduce carbon emissions, and improve supply chain efficiency.

Choose Deluxe Packaging for High-Quality Services

At Deluxe Packaging, we offer tailored solutions to meet your unique packaging needs! We specialize in creating innovative corrugated packaging designs that elevate your brand. With cutting-edge technology and a commitment to sustainability, we deliver high-quality solutions that stand out on the shelf.

Contact us today to discuss solutions for your specific needs or request a quote to get started.

Innovating Packaging With Plastic Corrugated Sheets: Lightweight, Durable, and Eco-Friendly

Plastic corrugated sheets have emerged as a game-changer for the packaging industry. This material combines the durability of plastic with the structural design of corrugation. It is typically made from polypropylene or polyethylene and features a series of parallel ridges and grooves. These make it a lightweight yet robust solution for various packaging needs.

This blog explores the key characteristics of these plastic corrugated sheets and how they are reshaping the packaging industry.

Key Characteristics of Plastic Corrugated Sheets

Plastic corrugated sheets possess a range of characteristics that make them a popular and versatile choice in packaging:

1. Lightweight Packaging

Corrugated plastics provide a lightweight alternative to traditional packaging materials. The inherent lightness of the sheets becomes a strategic advantage, enabling businesses to optimize logistics without compromising the integrity of the packaging.

2. Durable Protection

Despite their lightweight nature, corrugated plastic sheets are durable and impact-resistant. This ensures that packaged goods are well-protected during transit, minimizing the risk of damage or breakage. It helps maintain product quality from manufacturer to end-user.

3. Design Versatility

Unlike rigid and less adaptable packaging materials, plastic corrugated sheets offer unparalleled design versatility. Manufacturers can mold these sheets into various shapes and sizes, providing a customized packaging solution for every product.

4. Eco-Friendly Solutions

Most corrugated plastic sheets are recyclable, and some are made from recycled materials. This reduces the ecological impact of packaging waste, supports a business’s sustainability initiatives, and meets the expectations of environmentally conscious consumers.

5. Cost Effectiveness

The affordability of this packaging material is further highlighted by its lightweight design, which contributes to cost savings in shipping and transportation. This makes them an attractive choice for businesses seeking to enhance their bottom line without compromising on the quality and security of their products.

Common Uses of Plastic Corrugated Sheets in Packaging

Here are ways how plastic corrugated sheets are used in packaging:

  • Customizable boxes and cartons: This material is widely used to create custom-sized boxes and cartons, ensuring a precise fit for products and optimizing packaging efficiency.
  • Dividers and inserts: These sheets are ideal for crafting dividers and inserts within the packaging to provide additional protection and organization. They prevent items from shifting during transit, minimizing the risk of damage.
  • Protective layering: Plastic corrugated sheets are an effective protective layer for goods during shipping. They act as a buffer against impacts and vibrations to safeguard products.
  • Point-of-purchase displays: The design versatility of these sheets allows for the construction of attractive displays that showcase products in retail settings, enhancing product visibility and marketing efforts.
  • Promotional packaging: Companies utilize these sheets for creating eye-catching designs and branding. The printable surface of these sheets allows for vibrant graphics, logos, and product information, enhancing the overall presentation.
  • Protective wrapping: As a protective wrapping material, these plastic sheets can be wrapped around individual items or pallets. This offers an additional layer of defense against scratches, dents, and other forms of damage.

Deluxe Packaging: Your Trusted Source of Customized Corrugated Plastic Solutions

Deluxe Packaging has been a trusted name in cost-effective and eco-friendly packaging since 1982. We help take businesses’ packaging solutions to the next level with our extensive range of customized corrugated plastic options. In addition, we offer additives for UV protection, anti-static properties, flame retardancy, custom colors, and more. Our 100% recyclable products help meet essential sustainability goals while positioning your brand as a responsible leader in your industry.

Contact us today to explore tailor-made solutions for your specific needs! You can also request a quote to get started.

The Set-Up Boxes Revolution: Transforming Packaging With Elegance and Durability

Click to ExpandTransforming Packaging With Elegance and Durability

Set-up boxes are rigid and durable containers typically used for high-quality products. They consist of two parts: a base and a lid, both pre-assembled and set up in their final form before use. These boxes are known for their sturdiness and visual appeal, making them ideal for luxury items like cosmetics, electronics, and other premium goods.

This article examines the main advantages of set-up boxes and their increasing use in various industries. We’ll look at how they improve the unboxing experience and their practical applications in modern packaging.

The Advantages of Set-Up Boxes in Modern Packaging

The following benefits of set-up boxes make them a popular choice for a wide range of products across diverse industries:

Sturdiness and Protection

Set-up boxes are crafted with durability in mind, providing a protective enclosure for products. The sturdy construction ensures that items inside the box are shielded from potential damage during handling, shipping, and storage. This reliability is especially crucial for delicate or high-value goods, offering a secure solution that instills confidence in manufacturers and consumers.

Premium Presentation

The rigid structure and clean design of the set-up boxes contribute to an upscale aesthetic, making them an ideal choice for luxury products. Their visual appeal enhances the perceived product value and creates a positive first impression among consumers about the brand’s quality and exclusivity.

Customization Options

Set-up boxes provide a high degree of customization, allowing brands to tailor packaging to their unique specifications. Manufacturers can easily adapt these boxes’ size, shape, and design to align with branding requirements. This flexibility ensures that the packaging solution effectively communicates brand identity, attracts consumer attention, and differentiates products in a competitive market.

Versatility in Printing

The smooth surface of set-up boxes offers an excellent canvas for high-quality printing. Brands can use this printing versatility to showcase intricate designs, vibrant colors, and detailed product information. This capability enhances the packaging’s visual impact, allowing for more effective storytelling, branding, and marketing.

Reusability and Recyclability

Many set-up boxes can be crafted from recyclable materials, addressing the growing demand for eco-friendly packaging solutions. Their reusability also adds value for consumers and encourages a more sustainable and responsible approach to packaging. This dual emphasis on recyclability and reusability demonstrates a dedication to lowering the overall environmental impact of packing materials.

Ease of Assembly

The pre-assembled nature of set-up boxes streamlines the packaging process for manufacturers. This feature saves time, reduces labor costs, and ensures consistent product assembly. It also enhances production efficiency, enabling manufacturers to quickly meet customer demand without compromising quality.

Applications of Set-Up Boxes

The following applications showcase the versatility of set-up boxes across various industries:

  • Collectibles and memorabilia: limited-edition books, art prints, or other premium mementos
  • Cosmetics and beauty products: perfumes, skincare products, and makeup palettes
  • Electronics packaging: smartphones, tablets, and high-quality audio and video equipment
  • Food and confectionery packaging: chocolates, pastries, and other indulgent desserts
  • Jewelry packaging: rings, necklaces, earrings, anklets, and watches
  • Luxury goods packaging: high-end fashion items, premium watches, and limited edition or exclusive products
  • Medical and pharmaceutical packaging: medical devices, diagnostic kits, and other medical products
  • Promotional kits: a combination of products, samples, and marketing materials
  • Wine and spirits packaging: beers, liquors, wines, and other alcoholic beverages

Choose Deluxe Packaging for High-Quality Packaging Solutions

Since 1982, Deluxe Packaging has stood as an industry leader in the dynamic field of custom packaging design and implementation. We have excelled in creating captivating point-of-purchase (POP) displays that strategically enhance product visibility and customer engagement. Our influence extends far and wide, particularly in the Philadelphia metropolitan area.

Contact us for more information! You can also request a quote for your packaging needs.

Unveiling the Strength of Corrugated Plastic Sheets: A New Era in Packaging

Corrugated plastic sheets (or coroplast sheets) are extruded twin-wall plastic often used for packaging, signage, and construction purposes. They are made from polypropylene or polyethylene and are known for their parallel ridges and furrows on their surfaces, creating a corrugated pattern. This design offers unique advantages, making them suitable for various applications.

This article shares the different characteristics of corrugated plastic sheet materials and their diverse applications in the packaging industry.

Key Properties of a Corrugated Plastic Sheet

The following properties of corrugated plastic sheets play a pivotal role in their widespread use across various industries:


These sheets are designed with a corrugated pattern that enhances their structural integrity. This makes them highly resistant to impacts, ensuring they can withstand external pressures without compromising their integrity. They also exhibit impressive tensile strength, making them suitable for applications where the material must endure stretching or pulling forces.

Resistance to Moisture and Chemicals

The materials used to produce a corrugated plastic sheet are inherently moisture-resistant. This is highly advantageous for applications where exposure to water or high humidity is a concern. In addition, they are resistant to various chemicals, adding to their suitability for applications where contact with corrosive substances is likely.


Corrugated sheets are easy to cut, fold, and shape, allowing for versatility in design and application. Because of this, they apply to a wide range of industries and uses. Moreover, the smooth surface of a corrugated plastic sheet makes an ideal printing substrate. This functionality is frequently used in applications like signs and advertising displays.


Using corrugated sheets can provide you with notable environmental advantages. For one, their resilience increases product lifespan, reducing the need for frequent replacements. In addition, these sheets contribute to sustainable operations as a green alternative to non-recyclable materials, matching the modern industry’s growing demand for eco-friendly solutions. They also offer an energy-efficient manufacturing technique and the ability to be reused.


Corrugated plastic sheets are cost-effective due to their inherent durability, which eliminates the need for regular replacements. The material’s lightweight nature adds to reducing transportation costs, while its adaptability minimizes the need for numerous components. Furthermore, its manufacturing process is resource-efficient, resulting in decreased production costs.

Uses of a Corrugated Plastic Sheet in Packaging

The unique properties of corrugated sheets make them advantageous in the packaging industry. Here are common ways this material is utilized:

  • Protect fragile goods: Corrugated sheets safeguard delicate items during transit. The material’s shock-absorbing properties and resilience against impact make it an ideal choice for packaging electronics, glassware, and other breakable products.
  • Fit unique products: Corrugated plastic’s flexibility in shaping allows manufacturers to create custom-fit packaging for products with unique shapes and dimensions.
  • Ensure food product safety: Corrugated sheets are ideal for food packaging due to their resistance to moisture and chemicals, ensuring the freshness and uncontaminated state of perishable items.
  • Promote brands: Beyond their protective qualities, corrugated plastic sheets are effective marketing tools. The smooth surface provides an excellent canvas for vibrant graphics and branding, enhancing brand visibility through packaging.

Get Tailored Corrugated Plastic Solutions at Deluxe Packaging

If you need high-quality packaging solutions, look no further than Deluxe Packaging! We offer diverse stock and custom corrugated plastic sheet solutions for your needs. From size and thickness specifications to specialized additives like ultraviolet protection or anti-static properties, we tailor plastics to meet the demands of your unique applications.

Contact us today to explore the full range of our corrugated plastic capabilities! You can also request a quote now.

Types of Point-of-Purchase (PoP) Displays

Point-of-purchase (PoP) displays are promotional or marketing displays strategically placed in certain areas of a business or store to attract potential customers and promote products.

PoP displays can either be permanent or temporary, depending on your marketing goals. But, before settling on PoP displays, you should consider other factors such as cost, where you plan to place them within your store, and what products you want in the display. 

In this blog post, we will cover several popular types of PoP displays their benefits, and applications.

Shelf Talkers

Shelf talkers are strategically placed signs that stick out into store aisles to grab a shopper’s attention. They range from simple posters providing general information about a product to unique ones with colorful graphics telling people about new products and offers available. 

For example, a shelf talker promoting a new type of vitamin could be a three-dimensional, freestanding cardboard cutout with colorful graphics to attract attention. The messaging on the cutout could communicate the benefits of the product, unique selling points, and/or discount information to encourage shoppers to purchase immediately.

The following are the key advantages of using shelf takers for your retail display.

  • Eye-Catching: Grabs shoppers’ attention with signage protruding into the aisle.
  • Informational: Conveys product details effectively.
  • Versatile: They can be simple posters or intricate 3D displays.
  • Flexibility: They are easy to remove or replace depending on your needs.

End Caps 

End caps are one of the most common PoP displays found in retail stores. As their name implies, they’re located at the end of every shelf or aisle to provide product visibility and save customers from having to move down the aisle to check out a product. They are also highly effective for showcasing new or discounted products. 

Here are some key advantages of end caps.

  • High Visibility: Located at the end of aisles, ensuring maximum exposure.
  • Efficient Use of Space: They don’t take up too much space, and they’re ideal for stores with too many products and little space.

Vendor Shop/Store Within a Store 

Vendor shops help brands stand out from their competitors when selling products in a large outlet such as a supermarket. They create a mini retail store in a dedicated space within a large outlet exclusively featuring only their products. This method is the most elaborate and immersive type of retail PoP display. 

Advantages of having a store within a store include: 

  • Boosts Brand Visibility: Shoppers notice and remember the brand.
  • Exclusive Environment: Reinforces brand identity within a larger store and distinguishes your business from other brands. 

Floor Graphics

Well-designed floor graphics are unique PoP displays that brands can use to stand out. The simplest forms of floor graphics are foot graphics that guide people through a store or provide directions. However, brands are getting creative and designing elaborate floor graphics such as decals that resemble spilled products, giant holes, or even interactive games on the floor as part of marketing.

Other benefits include the following:

  • Creative Impact: Captivates customers with visually appealing designs.
  • Interactive: Floor graphics are highly effective because they are novel and unexpected. When used for games and other entertaining elements, they can engage people, prompting them to stay longer in the designated area.
  • Cost-effective: Utilizes store floor space creatively.

Free Standing Displays

Freestanding display units (FSDU) are standalone PoP floor displays. They don’t require external support and stand independently on the sales floor, making them ideal for temporary installations such as seasonal promotions. 

Their key features include:

  • Versatility: You can place them anywhere within a store to maximize visibility.
  • Customizable: They come in various shapes, sizes, and designs, making them highly customizable to fit a brand’s aesthetics and promotional needs.
  • Prominence: They often occupy prominent positions within a store, allowing products to catch the eye of shoppers.

Dump Bins

Dump bins are bin-shaped container display units designed to hold and showcase various small or loose products. The term “dump bin” comes from the idea that products are loosely dumped into a container for easy access by customers, promoting spontaneous buying decisions. They’re a good choice for small items that shoppers can quickly grab and continue shopping, such as gum and candy. The best way to design your dumb bins is to create unique and eye-catching designs that are more likely to attract consumers. 

Dumb bins are also:

  • Convenient for Shoppers: Allowing easy access to small items.
  • Space-Efficient: Maximizing product visibility in a small footprint.
  • Design Flexibility: Unique and creative designs can attract attention.

PoP Displays from Deluxe Packaging 

The design team at Deluxe Packaging collaborates with customers from various industries to create floor, counter, and power wing display solutions that deliver personalized and memorable purchasing experiences. From graphic design services to offset lithography printing, we can craft unique and powerful advertising solutions for nearly any application or environment.

Visit our PoP Displays page to explore our range of PoP display solutions and transform your brand’s in-store presence. You can also request a quote or contact us for more information.

Types of Setup Boxes/Rigid Boxes

Types Of Setup Boxes Rigid Boxes

Click to enlarge infographic

Also known as setup boxes, rigid boxes are a type of packaging often associated with luxury items and an unforgettable unboxing experience. Setup box packaging is made of high-quality materials such as chipboard or paperboard and is often lined with luxurious finishes like velvet, suede, or silk. They are sturdy, rigid, and thicker than an average folding carton.

Companies can customize rigid boxes to fit any product or brand, with options for unique shapes, sizes, and colors. Learn more about the types of rigid boxes, their applications, and their benefits so that you can select the right options for your products.

Types of Rigid Boxes

There are two main types of rigid boxes: partial finish and full finish.

Partial Finish

Partial finish rigid boxes have an outer layer that leaves the chipboard material inside visible. The wrapping only goes up to the inner edges of the box, and the chipboard usually has pierced creases to facilitate folding and fastening. Thus, partial finish boxes are easier to make, require fewer materials, and save production time while still producing an excellent final product.

Full Finish

Full finish rigid boxes have a complete covering that hides the chipboard material inside. These boxes are thicker, with 2-3 millimeters of chipboard. Different pieces of chipboard make up each side of the box, and finishing options are available as needed. Full finish boxes have a wrap that can be either white or printed.

Applications of Rigid Boxes

Rigid packaging material is commonly used in these packaging sectors:

  • CBD boxes
  • Candle boxes
  • Cigar boxes
  • Cosmetic boxes
  • Chocolate boxes
  • Display boxes
  • Gift boxes

Here is an overview of the various ways rigid boxes are used in these contexts.


Custom rigid boxes offer an elegant and easily accessible packaging solution, making them ideal for high-end gifts and luxury packaging. The extra details and protection make the gift more attractive and appealing to its target audience.


Rigid boxes offer extra protection for fragile products. Made of durable materials, these boxes can be stacked easily and can keep your products in good condition during storage.


To use rigid boxes as display boxes for retail purposes, you can design them with catchy and unique designs. This will draw your target audience’s attention, convert that audience to customers, and improve your bottom line.

Brand Promotion

Custom rigid cases are an effective tool for promoting your brand due to their built-in marketing features. You can use creative wrapping techniques and custom-print eye-catching branding information directly onto the boxes. This will help you stand out from your competitors and achieve maximum brand exposure.


If you want to ship your products safely and cost-effectively, consider using custom rigid boxes. These containers will protect your items during transportation and ensure they arrive in customers’ hands in pristine condition. Durable but light, these boxes can also help reduce shipping costs.

Advantages of Rigid Boxes

Durable & Protective

Rigid boxes are constructed from strong materials and feature a chipboard frame that is 1-3 mm thick, ensuring that it can withstand moderate stress and rough handling. These features offer enhanced protection for items during shipping, storage, and display.


Rigid cardboard boxes are an environmentally friendly packaging solution. Cardboard, the main material for manufacturing these boxes, is recyclable and biodegradable.


Rigid boxes are highly flexible and can be modified to meet specific needs, making them an excellent packaging choice. They enhance a product’s perceived value on the shelf, making it more attractive to customers and boosting brand recognition.

Diverse Design Options

Custom rigid boxes—especially luxury rigid boxes—offer unique and impressive packaging design options for businesses. The design options for these boxes are nearly endless, including shoulder neck boxes, sleeves, hexagonal boxes, boxes with windows, and more. These options allow businesses to choose a design that best suits their needs and impresses their customers with an elegant and eye-catching package.

Rigid Setup Boxes From Deluxe Packaging

Whether you’re shipping fragile items, looking to reduce your environmental impact, or wanting to make a lasting impression on your customers, rigid boxes are a great choice. If you’re interested in incorporating these types of boxes for packaging your products, let Deluxe Packaging help.

Our team of experts can help you find the perfect packaging solution for your needs. Learn more about our rigid setup boxes, request a quote, or contact us today.

What Is Foam Packaging?

Packaging foam material supports products during transportation and storage, preventing damage from external forces and handling. It is a preferred medium used in shipping due to its minimal weight and versatility for cushioning products of all sizes. Foam packing supplies come in several customizable options to provide a solution for various applications. We will explain why foam is used in packaging, the different types available, and the applications that benefit from foam packaging.

Why Is Foam Used in Packaging?

Foam provides cushioning and protects the product from scratches and abrasion during transit. Foam packing is versatile, available in bag, peanut, sheet, block, and roll form, depending on the product’s needs. Foam is also moisture-proof, protecting the packaged product from getting wet during shipping in the rain. Its soft surface is ideal for polished wood, ceramics, glass, and other fragile items that require delicate yet strong packaging.

Packaging foam materials provide a tight fit for products of any dimension or shape. Foam-in-place and foam-in-bag packaging are especially valuable for securing products in place with cushioning. Packaging companies can cut foam blocks, sheets, and rolls to the dimensions needed to provide adequate cushioning and a clean presentation.

Various types of foam packaging can suit different applications and budgets. There are reusable options, those that can reduce static and shock, and other options that we will discuss below.

Packaging Foam Types

There are three primary types of packaging foam materials. To select the option with the best abrasion protection and cushioning ability, determine your product’s weight, fragility, and optimal positioning. Also consider the aesthetics you’re aiming for. Foam packaging materials can be reusable, water-resistant, and aesthetically appealing to meet your requirements.

Here are the foams most commonly used in the packaging industry:

  • Polyurethane Foam: This is a versatile foam that provides excellent resilience and durability. Polyurethane foam is available in various densities and colors to create a functional and appealing product for any application. Featuring a sponge-like texture, polyurethane foam offers sound-dampening, moisture-absorbent, and cushioning properties. Polyurethane foams are often used as inserts to protect instrumentation, electronics, cosmetics, and appliances during transit.
  • Cross-Linked Polyethylene (XLPE): This compact, high-density, and closed-cell foam is an ideal choice for protecting goods from water, chemicals, and surface damage. It is most common for protecting medical equipment and other sensitive products during transit because it generates minimal particulates. XLPE is available in anti-static formulations and can be used in multi-part presentation kits due to its luxurious look and feel.
  • Expanded Polypropylene/Polyethylene (EPP/EPE): Expanded EPP or EPE foam materials offer excellent cushioning, impact resistance, and durability. They also have low compressive creep, allowing the material to return to its initial shape even after continuous loading. EPP and EPE have half the density of other materials yet provide the same level of cushioning. Thus, they minimize waste because less of the material is needed to provide adequate protection. Unlike XLPE, expanded EPP and EPE are recyclable.

Uses and Benefits of Packaging Foam

Packaging foam provides several benefits, including:

  • Prevents chips, scratches, and other damage to fragile items
  • Protects products from moisture
  • Some varieties (like low-density polyethylene, EPE, and EPP packaging foam) are recyclable
  • Anti-static varieties of foam protect electronic goods from static and shock-related damage
  • Comes in different forms to fit various applications
  • Cost-effective and lightweight, minimizing shipping costs
  • Do not leave marks or scratches

These products and industries particularly benefit from packaging foam during transportation and storage:

  • Acupuncture equipment
  • Appliances
  • Cameras
  • Consumer products
  • Electronics
  • Machine parts
  • Medical devices
  • Musical instruments
  • Office equipment
  • Toys

Foam Packaging Solutions From Deluxe Packaging

Foam packaging comes in various forms and material options to protect goods from scratches, vibration, moisture, and static-related damage. Packaging foam types can also be reusable or visually appealing for applications like display cases. Foam is an ideal packaging material due to its versatility and minimal weight, which reduces shipping costs.

Deluxe Packaging has been delivering high-quality, cost-effective packaging solutions since 1982. We meet the unique needs of our domestic and international customer base by delivering innovative, 100% recyclable packaging solutions. Browse our custom foam insert capabilities to find a solution that works for your products. Contact us or request a quote to learn more about our foam packaging services.

Common Uses for Corrugated Plastic

Corrugated plastic features flutes or channels sandwiched between two flat layers of plastic material. This design gives the material added strength, flexibility, and durability. Corrugated plastic is extruded from plastic resins into sheets, and manufacturers can use the material to create various products, such as packaging, signage, and more. Learn more about the different applications of corrugated plastic.

What Can Corrugated Plastic Be Used For?

Corrugated plastic is light, durable, and resistant to water and chemical degradation. It’s longer-lasting than corrugated cardboard, which softens as it gets wet. Corrugated plastic can be printed with vibrant colors or graphics and constructed into various three-dimensional forms and cut-outs. Specialty corrugated plastic can also be strengthened with additives that make the final product flame retardant, UV-resistant, and anti-static. These are some of the most common applications for corrugated plastic.


Corrugated plastic manufacturers can create custom boxes and inserts from the material, making it an easy choice for packaging. Corrugated plastic protects loose items in a container during shipment and storage. Most corrugated plastics are fabricated from polypropylene resins, which are non-toxic, BPA-free, and won’t emit dangerous chemicals in extreme temperatures like hot warehouses or trucks.


Corrugated plastic can be used to print both indoor and outdoor signage, such as:

  • Political signs
  • Real estate signs
  • Promotional signs
  • Retail sale notices

Construction sites also use corrugated plastic signs because they are durable, reusable, and are able to hold clear messages after long periods of time in the elements. Corrugated plastic is cost-effective, so commercial organizations and individuals can easily budget for numerous signs and potential replacements over the course of a promotion or construction project.

POP & Trade Show Displays

Excellent promotional material is key to a successful marketing campaign. Whether a company is launching a grand opening at a new retail location, requires eye-catching displays for a pop-up store, or is networking at a niche industry trade show, having the right hardware is crucial.

Corrugated plastic is a versatile solution for retail point-of-purchase (POP) and trade show displays. Manufacturers can build permanent POP displays or temporary foldable structures that can easily be packed away and reused for each new event. Companies can print graphics, promotional messages, and bright colors onto corrugated plastic POP displays, making them an aesthetically appealing, convenient, and cost-effective choice.

Floor Coverings

Corrugated plastic sheets can cover the floors of in-progress construction sites to protect the floors from paint, debris, work boots, and more. The material is lightweight, easy to move around as needed, and provides a comfortable, secure walking surface. Users can clean corrugated plastic floor covers for reuse across multiple jobs.

In Buildings

Builders and contractors can use corrugated plastic to create templates for countertops and other custom installations. Users can easily ensure the actual material is the same size and shape as the corrugated plastic placeholder.

Corrugated plastic can also be used as storm shutters that are stronger than glass and lighter than plywood. Translucent corrugated polycarbonate is often found in sunroom and greenhouse roofing, where they provide some thermal insulation and let in light.

Pet Enclosures

Corrugated plastic has the durability and structural integrity to form lightweight enclosures for small pets like rabbits, hamsters, and gerbils. Because the material is non-toxic, easy to clean, and repels moisture exposure, it’s a convenient option for temporary and long-term enclosures.

Corrugated Plastic From Deluxe Packaging

Corrugated plastic is a versatile material for a variety of consumer, commercial, and industrial applications. It can be manufactured to be fire retardant, UV-resistant, corrosion-resistant, and antistatic. At Deluxe Packaging, we provide custom packaging design and construction using high-quality corrugated plastics in a range of thicknesses, colors, and other specifications.

Based in Philadelphia, we are a regional and international leader in packaging solutions, serving customers in Asia and Europe. Our customers partner with us for our expertise, competitive pricing, and range of options. Browse our corrugated plastic service page for more information. Contact us today to learn more about our capabilities, or request a quote to start your order.