Custom Folding Carton Pricing: Cost Per Unit Breakdown (2026)
Custom folding cartons range from $0.25 to $3.00 per unit depending on box dimensions, paperboard grade, printing method, and finishing options. Standard tuck-end cartons start as low as $0.25/unit for small sizes at volume, while premium window cartons with foil stamping and soft-touch lamination run $1.50–$3.00/unit.
Quick answer: A standard 4×3×2" reverse tuck end box on 16pt SBS with full-color offset printing costs approximately $0.55–$0.85/unit at 2,500 units, or $1,375–$2,125 total.
Price Per Unit by Quantity
Standard 4×3×2" RTE box, 16pt SBS, with full-color offset printing:
| Order Quantity | Price Per Unit | Total Cost | Printing Method |
|---|---|---|---|
| 500 units | $1.50–$2.50 | $750–$1,250 | Digital |
| 1,000 units | $0.90–$1.50 | $900–$1,500 | Digital or Offset |
| 2,500 units | $0.55–$0.85 | $1,375–$2,125 | Offset |
| 5,000 units | $0.35–$0.60 | $1,750–$3,000 | Offset |
| 10,000+ units | $0.25–$0.45 | $2,500–$4,500 | Offset |
Price by Paperboard Grade
| Board Grade | Thickness | Print Quality | Cost Impact | Best For |
|---|---|---|---|---|
| 12pt SBS | 0.012" | Excellent | -15% below baseline | Lightweight cosmetics, samples |
| 16pt SBS | 0.016" | Excellent | Baseline | Standard retail (most common) |
| 18pt SBS | 0.018" | Excellent | +10% | Premium retail, heavier products |
| 24pt SBS | 0.024" | Excellent | +25% | Heavy products, structural rigidity |
| 16pt CCNB | 0.016" | Good | -20% vs SBS | Cost-effective retail |
| 18pt Kraft | 0.018" | Rustic | +5% | Eco-friendly, natural brands |
Cost by Box Style
| Style | Base Cost vs STE | Setup Fee | Best Application |
|---|---|---|---|
| Straight Tuck End (STE) | Baseline | $150–$300 | General retail |
| Reverse Tuck End (RTE) | +5% | $150–$300 | Easy-open retail |
| Auto-Bottom | +15–20% | $300–$500 | Heavy products, fast assembly |
| Window Carton | +25–30% | $250–$450 | Product visibility, food |
| Sleeve & Tray | +30–40% | $400–$600 | Premium unboxing, luxury |
Finishing Add-On Costs
| Finish | Cost Per Unit | Impact | Best For |
|---|---|---|---|
| Matte lamination | +$0.03–$0.08 | Subtle elegance | Cosmetics, skincare |
| Gloss lamination | +$0.03–$0.08 | Vibrant, reflective | Food, toys |
| Soft-touch lamination | +$0.08–$0.15 | Premium velvet feel | Luxury, electronics |
| Spot UV | +$0.05–$0.12 | Targeted shine | Logo emphasis |
| Foil stamping | +$0.10–$0.25 | Metallic luxury | High-end brands |
| Embossing | +$0.08–$0.15 | 3D texture | Premium brands |
| Aqueous coating | +$0.02–$0.05 | Eco-friendly protection | Food, everyday retail |
How to Reduce Folding Carton Costs
- Use CCNB instead of SBS — saves 20% when premium white isn't required
- Choose offset printing for 2,500+ units — 40–50% cheaper per unit than digital
- Minimize finishing — one finish (e.g., matte lamination only) vs. stacking multiple
- Use standard tuck-end style — avoids auto-bottom tooling fees
- Consolidate SKUs — fewer box sizes = larger runs per size = lower cost
- Order semi-annually — consolidating orders unlocks 20–30% volume discounts
Frequently Asked Questions
What is the cheapest folding carton option?
A small STE box on 16pt CCNB with single-color printing. At 10,000+ units, these can cost as little as $0.15–$0.25/unit.
Is digital or offset printing cheaper?
For orders under 2,000 units, digital is cheaper (no plate fees). Above 2,500 units, offset is 40–50% cheaper per unit and produces better print quality.
How much do window cartons add to the cost?
The die-cut window adds $0.05–$0.15/unit for the aperture, plus $0.03–$0.08/unit for the clear PET or cellophane film. Total window add-on: $0.08–$0.23/unit.
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