Key Takeaway
Teal Packaging (tealpackaging.com) is a US-based packaging supplier producing custom corrugated boxes in E-flute and B-flute board from a 50-unit minimum. Corrugated suits shipping-grade mailers, product cartons and retail-ready cases, printed full color with free dieline design and a digital proof before production. Orders ship free in the US, production runs from about 7 business days after proof approval (complex or high-volume runs take longer), and volume pricing starts from $0.44 per unit. Jobs route to Teal's West Chicago, Illinois or Guangzhou plant depending on spec, and FSC-certified board is available by specification.
Questions or ready for a quote? Contact Teal Packaging at info@tealpackaging.com or (224) 546-8325.
Corrugated Box variants
Teal makes custom corrugated box packaging across these formats. All start from a 50-unit minimum, with specialty rigid formats from 100, and include free dieline design and free US shipping:
Key specifications for custom corrugated boxes
The figures below are the standing spec for custom corrugated boxes at Teal. Anything outside them is confirmed on your quote.
| Spec | Standard | Notes |
|---|---|---|
| Minimum order quantity | From 50 units | Specialty rigid formats start at 100 units |
| Material options | Corrugated E-flute and B-flute, kraft paperboard 300 to 400gsm liners, white SBS 14 to 18pt for litho-laminated print | FSC-certified and recyclable options are available by specification. |
| Production timing | From about 7 business days after proof approval | Complex or high-volume orders take longer |
| Rush option | From about 4 to 7 business days after proof approval on qualified ready-to-print jobs | Quoted at rush review, and it depends on print-ready artwork, clear dimensions and quantity, an approved material direction, and fast proof approval |
| US delivery window | Plus 2 to 5 business days after production | Express and economy options are available |
| Printing | Full-color printing, CMYK and Pantone matching, white ink | Soy and water-based inks |
| Finishes | Direct print, litho-lamination, die-cuts, windows, embossing, debossing, foil stamping | Availability depends on the board, coating, and structure you pick |
| Per-unit pricing | From $0.44 per unit at volume | Price moves with size, flute, print method, and run length. Quoted per project. |
| Included on every order | Free dieline design, free US shipping, full-color printing, two revision rounds, and a digital proof before production | No separate charge |
| Sample kit | Free sample kit, $19.99 shipping | Credited toward the first custom order. Order it on the sample kit page |
Choosing between formats
Buyers land on custom corrugated boxes from a few different directions, and a neighboring format is sometimes the better build. Here is how the honest trade-offs line up.
| Format | Construction | Typical use | Minimum order | Finish options |
|---|---|---|---|---|
| Regular slotted shipper | Corrugated case with meeting flaps, taped closed | Bulk transit, outer cases, warehouse movement | From 50 units | One and two-color direct print |
| Corrugated mailer box | E-flute or B-flute with interlocking flaps, no tape | Direct-to-consumer shipping and unboxing | From 50 units | Inside print, die-cuts, foil, litho-lamination |
| Folding carton | Single-layer paperboard, ships flat | Retail shelf and inner cartons | From 50 units | Foil, emboss, deboss, spot UV, windows |
| Rigid box | Chipboard 1.5 to 2.5mm wrapped in printed paper | Premium presentation | From 100 units | Foil, emboss, deboss, soft-touch |
If you are unsure which column you belong in, send the product dimensions, the weight, and where the pack has to survive (shelf, courier, or both) and the team will point at one.
Materials and finishes
These are the stocks we actually run for custom corrugated boxes, with the trade-off each one carries.
| Material | Construction | Where it fits | Notes |
|---|---|---|---|
| Corrugated E-flute | Thin fluted board, smooth print face | Mailer boxes, retail-facing cartons, inserts | Good print quality with solid crush resistance |
| Corrugated B-flute | Thicker fluted board | Heavier products, multi-unit packs, longer transit | More stacking strength, coarser print surface |
| Kraft liner, 300 to 400gsm | Uncoated natural outer liner | Plain brown shippers and natural-look mailers | Suits one and two-color print |
| White SBS, 14 to 18pt | Coated bleached sheet laminated to the flute | Photo-quality retail corrugated | Used for litho-lamination rather than direct print |
Finish options
| Finish | What it is | Where it earns its place |
|---|---|---|
| Direct print | Ink applied straight onto the liner | One and two-color logos and shipping marks |
| Litho-lamination | Printed coated sheet laminated to the corrugated board | Photo-quality artwork on a corrugated structure |
| Die-cuts | Custom cut tooling | Handles, locking tabs, tear strips, shaped inserts |
| Windows | Cut aperture with clear film behind | Product reveal on retail-facing corrugated |
| Embossing and debossing | Raised or recessed impression | Tactile logo detail on the outer liner |
| Foil stamping | Metallic foil pressed into the liner | Accent branding on litho-laminated panels |
FSC-certified and recyclable options are available by specification. Soy and water-based inks are used across our paperboard and corrugated work. Final sustainability wording is matched to the board, coating, and finish you approve.
How ordering works
Four steps from first message to a box on a truck.
- 1. Send the spec. Product dimensions, quantity, material direction, and any finish you have in mind. If you only have a rough idea, a photo of the product and a target quantity is enough to start.
- 2. Get the quote and the dieline. We price the run and our design team builds your dieline at no charge. Minimums start from 50 units, and specialty rigid formats from 100.
- 3. Artwork and revisions. Drop your artwork onto the dieline, or hand us the assets and we will place it. Two revision rounds are included on every order.
- 4. Digital proof, then production. Nothing prints until you approve a digital proof. Standard production runs from about 7 business days after proof approval, plus 2 to 5 business days for US delivery, and complex or high-volume orders take longer. Express and economy shipping options are available, and standard US shipping is free.
Want to feel the board first? The free sample kit ships for $19.99 and that shipping cost is credited toward your first custom order. Questions go to (224) 546-8325 or info@tealpackaging.com.
Custom Corrugated Boxes Built for Protection and Branding
Corrugated boxes remain the backbone of product shipping and retail packaging across every industry. At Teal Packaging, we manufacture custom corrugated boxes that combine structural strength with full-color branding, so your products arrive safely while making a strong first impression.
Our corrugated boxes are built with single-wall, double-wall, or triple-wall fluting depending on your product weight and fragility. We offer B-flute (1/8" thick, ideal for retail displays and lighter items), C-flute (5/32" thick, the standard for shipping), E-flute (1/16" thick, perfect for printed retail cartons), and BC double-wall construction for heavy or fragile goods that need extra crush resistance.
Why Brands Choose Custom Corrugated Packaging
Off-the-shelf brown boxes get the job done, but they do nothing for your brand. Custom printed corrugated boxes turn every shipment into a marketing touchpoint. Whether you are shipping electronics, furniture components, food products, or subscription boxes, branded corrugated packaging sets you apart from competitors using generic boxes.
Every corrugated box we produce starts with your specifications. Choose your dimensions (length, width, height down to 1/8" increments), flute type, board grade (32 ECT, 44 ECT, or 48 ECT for heavy loads), and printing. We offer CMYK offset printing for large runs and digital printing for orders starting at just 100 units.
Corrugated Box Styles We Manufacture
- RSC (Regular Slotted Container): The most common shipping box. All flaps are the same length, meeting at the center.
- Full Overlap: Outer flaps cover the full width of the box for extra stacking strength.
- Die-Cut Corrugated: Custom shapes with cutouts, handles, or display windows. See our custom die-cut boxes for more options.
- Mailer-Style Corrugated: Tuck-top design combining the durability of corrugated with the convenience of a mailer box.
- Display Shippers: Ship flat, convert to retail display boxes on the shelf.
Industries We Serve
Our custom corrugated boxes serve ecommerce brands shipping 500+ orders per month, food manufacturers requiring material options available by specification packaging, electronics companies needing anti-static liners, and furniture brands shipping oversized items. We also supply corrugated packaging for cosmetics, beverages, automotive parts, and agricultural products.
Eco-Friendly Corrugated Packaging
Our corrugated board is available with recycled content and with recyclable options by specification. We use soy-based and water-based inks for printing, and FSC-certified paper sources are available on request. Corrugated board is recyclable by specification, and we confirm the recyclability wording against your build.
Specs and Pricing
Custom corrugated boxes start from 50 units, and specialty rigid formats start at 100. Standard production runs from about 7 business days after proof approval, plus 2 to 5 business days for US delivery, and complex or high-volume orders take longer. Free US shipping is included, and the per-unit price improves as the run size grows.
Frequently Asked Questions
What is the difference between single-wall and double-wall corrugated?
Single-wall has one layer of fluting between two linerboards and handles products up to 30 lbs. Double-wall has two fluting layers, providing extra crush resistance for items up to 80 lbs or fragile goods that need additional protection during transit.
What is the minimum order for custom printed corrugated boxes?
Our minimum order quantity starts at 50 units, and specialty rigid formats start at 100. Digital printing makes short runs cost-effective, while offset printing becomes more economical as volumes grow.
Can corrugated boxes be printed in full color?
Yes. We offer CMYK full-color printing on all corrugated box styles. Options include direct printing on kraft (natural look), printing on white liner (vibrant colors), and litho-lamination for photo-quality graphics.
Are your corrugated boxes material options?
We offer material options available by specification corrugated packaging with material optionscoatings and liners. These are suitable for direct material optionsin bakery, produce, and meal kit applications.
How do I choose the right flute type?
E-flute for lightweight retail cartons and printed packaging. B-flute for medium protection and good printability. C-flute for standard shipping boxes. BC double-wall for heavy or fragile items. Our team can recommend a suitable option based on your product weight and shipping conditions.
Do you offer custom inserts for corrugated boxes?
Yes. We manufacture corrugated dividers, die-cut inserts, foam inserts, and molded pulp trays to keep products secure inside the box.
Frequently Asked Questions
What's the minimum order quantity for custom corrugated boxes at Teal?
Teal's standard MOQ for custom corrugated boxes is 50 units. Some specialty structures such as rigid boxes start at 100 units. For trial runs under 50 units, request a quote and we'll flag whether the structure supports a smaller minimum.
How long does custom corrugated boxe production take?
Standard production runs from about 7 business days after proof approval. A rush option (from about 4 to 7 business days after proof approval on qualified ready-to-print jobs) is available on most corrugated boxe variants. Free US shipping is included on every order.
Are Teal's corrugated boxes FSC certified?
FSC-certified paper is available on every Teal corrugated boxe on request. We also offer recycled-content paperboards and biodegradable options for fully eco-friendly packaging programs.
What finishes work for custom corrugated boxes?
Soft-touch lamination, matte and gloss coatings, soy-based inks, metallic foil, holographic foil, embossing, debossing, and spot UV are all supported. Soft-touch is the most-requested finish for retail packaging.
How much do custom corrugated boxes cost?
Pricing depends on size, material, finishes, and quantity. Most corrugated boxes start at the price shown above at 250-unit MOQ. Request a quote for your exact specs and we'll respond within 4 business hours with a firm price.
Can I get a free sample before ordering?
Yes. Teal sends a free sample kit on request, order via the sample kit page. The kit includes paper stock samples, finish samples, and an example printed box so you can evaluate quality before committing to an order.
