Custom Packaging Without the 1,000-Box Minimum
Most packaging companies require minimums of 1,000 to 5,000 units. That puts custom packaging out of reach for startups, Etsy sellers, product launchers, and brands testing new products. You do not want to commit to 5,000 boxes before you know if the design works or the product sells.
At Teal Packaging, our minimum order is just 100 boxes. That changes everything. You can test a design, validate your branding, ship your first batch of orders, and iterate based on real customer feedback without spending thousands on packaging that might be wrong.
How We Keep Minimums Low
Digital printing technology eliminates expensive setup costs. Traditional offset printing requires custom plates that cost $400 to $800 depending on design complexity. Those plate costs only make sense when spread across thousands of units.
Digital printing has zero plate costs. We print directly from digital files using inkjet or toner-based systems.
This means full CMYK color printing at any quantity. No setup fees, no plate fees, no minimum runs. You order 100 boxes, we print 100 boxes. The per-unit cost is higher at low volumes ($2.00 to $4.00/unit versus $1.00 to $1.80/unit at 1,000 qty), but the total investment is manageable.
On-demand production reduces inventory risk. We produce your boxes when you order them, not months in advance. This lets us run small batches economically without tying up warehouse space or cash in inventory.
Flexible manufacturing processes let us switch between jobs quickly. We can print 100 units of your design, then switch to another customer's design without the long changeover times that traditional printing requires.
What You Can Order at 100 Units
Custom mailer boxes with full-color printing. These are corrugated boxes that self-lock with tabs and slots. Full-color exterior graphics, optional interior printing. Sizes from 6x4x2" to 12x10x5". From $2.50/unit at 100 qty, dropping to $1.50/unit at 500 qty and $1.20/unit at 1,000 qty.
Folding carton boxes for retail products. Tuck-end, auto-lock, or crash-lock closures. Full-color printing with matte or gloss lamination. Custom sizes available. From $1.50/unit at 100 qty for basic folding cartons, $2.50/unit for boxes with windows or complex die-cuts.
Kraft boxes with branded printing. Natural brown kraft with 1 to 2 color logo printing. Perfect for artisan products, soap, candles, and food items. From $1.20/unit at 100 qty, dropping to $0.80/unit at 500 qty.
Cosmetic boxes for beauty product launches. Folding cartons with custom printing, UV coating, soft-touch finishes. Standard cosmetic sizes or custom dimensions. From $1.80/unit at 100 qty.
Soap and candle boxes for small-batch makers. Windowed kraft boxes or full-wrap printed designs. From $1.30/unit at 100 qty for basic soap boxes, $1.60/unit for candle boxes with custom inserts.
Rigid boxes for luxury products. Premium rigid chipboard construction with magnetic closures or lift-off lids. Minimum order is 50 units for rigid boxes (lower than most suppliers). From $5.50/unit at 50 qty, $4.50/unit at 100 qty, $3.50/unit at 300 qty.
Who Benefits from Low-MOQ Packaging
Startups testing product-market fit. You need to ship 50 to 200 orders to validate your product and branding. Ordering 5,000 boxes before you know if the design works is risky. Start with 100 units, get customer feedback, iterate if needed, then scale to 500 or 1,000 units once the design is proven.
Etsy sellers and small makers. If you sell 20 to 100 items per month, a 1,000-unit minimum means you are buying 10 months of inventory. That ties up cash and warehouse space. Order 100 to 250 units at a time to match your actual sales volume.
Product launchers and beta testers. Launching a new product with influencer kits, beta shipments, or a soft launch? You need professional packaging but only need 50 to 150 boxes. Low minimums let you create a great first impression without over-investing.
Seasonal or limited-edition products. Holiday packaging, special collaborations, or seasonal variants should not require 1,000-unit orders. Order 100 to 300 units for a limited run without leftover inventory.
Brands with multiple SKUs. If you have 10 product variations, ordering 1,000 boxes per SKU means 10,000 total boxes. That is unrealistic for most small brands. Order 100 to 250 boxes per SKU for manageable inventory levels.
Real Cost Examples at Small Quantities
8x6x3" mailer box with full-color printing: $3.50/unit at 100 qty ($350 total order). $2.00/unit at 250 qty ($500 total). $1.50/unit at 500 qty ($750 total). $1.20/unit at 1,000 qty ($1,200 total).
6x4x2" folding carton box with 2-color print: $2.00/unit at 100 qty ($200 total). $1.30/unit at 250 qty ($325 total). $0.90/unit at 500 qty ($450 total). $0.70/unit at 1,000 qty ($700 total).
10x8x4" kraft mailer with 1-color logo: $3.00/unit at 100 qty ($300 total). $1.80/unit at 250 qty ($450 total). $1.30/unit at 500 qty ($650 total). $1.00/unit at 1,000 qty ($1,000 total).
The per-unit cost drops 30% to 50% as you scale from 100 to 1,000 units, but starting small lets you test and iterate without massive upfront investment.
Scaling Your Packaging Orders
Most brands follow this progression: Order 100 units to test and launch. Reorder 250 units once you validate the design. Scale to 500 units when you hit consistent monthly volume. Move to 1,000+ units when you have predictable sales and cash flow.
This staged approach spreads your investment over time and lets you improve the design based on customer feedback. Many of our customers change their packaging design after the first 100 to 250 units based on what they learn. Starting small prevents expensive mistakes.
Design and Proofing Process
We provide digital design proofs via PDF or online mockup viewer. You approve the proof before we print. Changes are free during the proofing stage. Once you approve and we start production, changes cost extra.
Physical samples are available for $30 to $50 depending on box complexity. We strongly recommend ordering a physical sample before committing to 100+ units. Colors print differently than they appear on screen, and box dimensions feel different in person. A sample prevents surprises.
Pricing Breakdown by Box Type
Mailer boxes (100 qty): 6x4x2" for $2.50/unit, 8x6x3" for $3.50/unit, 10x8x4" for $4.50/unit. Interior printing adds $0.40/unit. Soft-touch coating adds $0.25/unit.
Folding cartons (100 qty): 4x4x2" for $1.50/unit, 6x6x3" for $2.00/unit, 8x6x4" for $2.50/unit. Windowed boxes add $0.30/unit for die-cut and film.
Kraft boxes (100 qty, 1-color print): 6x4x2" for $1.20/unit, 8x6x3" for $1.60/unit. Full-color kraft: $2.20/unit at 100 qty.
Rigid boxes (50 qty minimum): 8x6x3" for $5.50/unit at 50 qty, $4.50/unit at 100 qty, $3.50/unit at 300 qty. Magnetic closure adds $0.50/unit.
Minimum order: 100 units for mailers and folding cartons, 50 units for rigid boxes. No die fees on orders over 250 units. Free shipping on orders over $400. Production time is 7 to 12 days for digital printing.
Get low-MOQ custom packaging pricing. See volume pricing tiers.
