Product cartons

A product carton has to fit the product, the shelf and the pallet at the same time. Correct dimensions save more money over time than almost any other choice in a packaging project.

Get a free mockup Try the AI tool

Product cartons in several formats stacked in warm ivory tones

Dimensioning from three directions

We start from product dimensions plus necessary tolerance, then check how many cartons fit a shelf facing and how they lay out on a Euro pallet (1200 x 800 mm). A few millimetres of change is often enough to gain an extra layer per pallet, lowering freight cost per unit.

Material and strength

300-450 gsm board for single retail products.
Micro-flute when the carton must carry weight or be stacked.
Outer carton in B or BC flute for transporting multiple units.
Grain direction is set so the carton stands stably on the shelf.

Information and marking

Product cartons often carry a barcode, article number, contents and statutory information. We place the barcode on a flat area with sufficient quiet zone and avoid creases and lamination edges so it scans at the till.

Process and conditions

MOQ around 250-300 units; higher volumes clearly reduce unit price.
Lead time normally 6-8 weeks after confirmed design.
VyPack specifies and inspects; manufacturing takes place with selected suppliers.

Detail of the carton corner joint and the cross-section of the board

Material, structure and finish in detail

We review board quality, thickness, fit, print technique and finishing with you and turn it into a specification a supplier can produce against.

Try the AI tool Get a free mockup

FAQ

Frequently asked questions

How much tolerance does the product need?: Normally 1-3 mm per side depending on whether the product is soft, hard or has its own wrap. Too tight a fit increases damage during packing.
Can you optimise dimensions against a pallet?: Yes, and it is one of the most profitable steps. We calculate pallet patterns and suggest adjustments that do not affect the product.
Do I need both a product and an outer carton?: If the product is sold in store and shipped in multi-unit cases, yes. We dimension both together.
Can print match an existing range?: Yes, we work from your existing colour references and check against supplier proofs.

Folding cartonsThe folding carton is the workhorse of packaging: low weight, flat delivery and high print quality. The deciding detail is the structure: how the lid locks, how the base holds and how easily it assembles.Read more Display boxesA display box has to stand firmly, present the product at the right height and survive customers picking from it. The structure decides whether it still looks good at the end of the campaign.Read more Logistics & supply chain supportPackaging dimensions set freight cost in two legs: inbound to you and outbound to your customer. Optimising both at once is often the largest saving in a project.Read more MaterialsMaterial choice drives both feel and cost. The same structure can feel entirely different depending on whether the surface is uncoated, laminated or wrapped in a speciality paper.Read more

Get a free mockup

Tell us briefly about your project. We normally reply within one business day with suggestions, a price range and next steps.