Custom Corrugated Box Pricing: Cost Per Unit Breakdown (2026)
How Much Do Custom Corrugated Boxes Cost in 2026?
Custom corrugated boxes range from $0.50 to $6.50 per unit depending on box dimensions, board grade, printing method, and order quantity. Standard unprinted RSC shipping boxes start as low as $0.30/unit in bulk, while custom-printed branded shippers with premium finishes run $1.50–$6.50/unit.
Quick answer: A standard 12×10×6" RSC box with single-color flexographic printing on 32 ECT single-wall board costs approximately $1.20–$2.00/unit at 2,500 units, or $3,000–$5,000 total.
Price Per Unit by Quantity
Standard 12×10×6" RSC box, 32 ECT single-wall, with single-color flexographic printing:
| Order Quantity | Price Per Unit | Total Cost | Printing Method |
|---|---|---|---|
| 500 units | $3.00–$4.50 | $1,500–$2,250 | Digital |
| 1,000 units | $2.00–$3.50 | $2,000–$3,500 | Digital or Flexo |
| 2,500 units | $1.20–$2.00 | $3,000–$5,000 | Flexo |
| 5,000 units | $0.80–$1.50 | $4,000–$7,500 | Flexo |
| 10,000+ units | $0.50–$1.20 | $5,000–$12,000 | Flexo |
Price by Board Grade
| Board Grade | ECT Rating | Weight Capacity | Price Impact | Best For |
|---|---|---|---|---|
| E-Flute Single Wall | 32 ECT | Up to 40 lbs | Baseline | E-commerce mailers, lightweight items |
| B-Flute Single Wall | 32 ECT | Up to 65 lbs | +5–10% | Standard retail shipping |
| C-Flute Single Wall | 32 ECT | Up to 65 lbs | +10–15% | General shipping, most versatile |
| BC-Flute Double Wall | 48 ECT | Up to 120 lbs | +30–40% | Heavy items, pallet stacking |
| 44 ECT Single Wall | 44 ECT | Up to 95 lbs | +20–25% | Heavy-duty without double wall |
Printing Method Cost Comparison
| Method | Cost/Unit Add-On | Setup Fee | MOQ | Print Quality | Best For |
|---|---|---|---|---|---|
| Unprinted | $0.00 | $0 | Any | N/A | Budget shipping |
| 1-Color Flexo | +$0.20–$0.50 | $200–$400 | 1,000+ | Basic logo/text | B2B shipping |
| 3-Color Flexo | +$0.40–$0.80 | $600–$1,200 | 2,500+ | Multi-color branding | Branded shipping |
| Digital CMYK | +$0.80–$2.00 | $0 | 500+ | Full-color photo | Short runs, DTC |
| Litho-Laminated | +$1.50–$3.00 | $500–$1,500 | 1,000+ | Premium retail | Retail displays |
How to Reduce Corrugated Box Costs
- Right-size your box — Oversized boxes waste material and increase DIM weight shipping charges
- Use standard RSC style — Avoids custom die-cutting fees ($150–$400)
- Choose flexo printing for 2,500+ units — 40–60% cheaper per unit than digital
- Use 32 ECT single-wall unless your product exceeds 40 lbs
- Consolidate SKU sizes — Fewer box sizes = larger volume per size = lower cost
- Order quarterly — Larger consolidated orders unlock 20–35% volume discounts
Frequently Asked Questions
What is the cheapest type of corrugated box?
An unprinted RSC (Regular Slotted Container) in 32 ECT single-wall B-flute is the most cost-effective option. At 10,000+ units, these can cost as little as $0.30–$0.50/unit for standard sizes.
Is digital or flexo printing cheaper for corrugated boxes?
For orders under 2,000 units, digital is cheaper (no plate fees). For orders above 2,500 units, flexographic printing is 40–60% cheaper per unit despite the one-time plate cost of $200–$1,200.
How much does custom die-cutting add to the cost?
Custom die-cut shapes add a one-time tooling fee of $150–$400 plus a per-unit premium of $0.10–$0.30. This is justified for retail packaging where the custom shape enhances shelf appeal, but unnecessary for standard shipping applications.
Ready to price your custom corrugated boxes? Get a free quote or browse our corrugated box collection. Need guidance? Ask our AI packaging consultant.