How Much Does Custom Packaging Cost in 2026? Complete Pricing Guide
Key Takeaways
- Custom mailer boxes cost between $0.75–$3.50 per unit at quantities of 500+ (source: Cubit Packaging internal pricing data, March 2026)
- Custom rigid boxes range from $3.00–$15.00 per unit depending on size, greyboard thickness, and finish
- Stand-up pouches cost between $0.35–$2.00 per unit at production scale
- Ordering 1,000+ units typically reduces per-unit cost by 30–50% compared to 100-unit orders
- Premium finishes (foil stamping, embossing, spot UV) add $0.10–$0.75 per unit
- The global custom packaging market reached $41.2 billion in 2025 and is projected to hit $48.5 billion by 2028 at a 4.2% CAGR (Smithers Pira, 2025)
Definition: Custom packaging is packaging manufactured to a brand's specific dimensions, design, material, and structural requirements — as opposed to stock (off-the-shelf) packaging that comes in standardized sizes and cannot be modified.
Custom packaging is one of the most important investments a brand can make — but how much does it actually cost? Whether you are launching a new product line or refreshing your brand's look, understanding packaging costs helps you budget effectively and avoid surprises.
This guide breaks down real-world pricing for every major type of custom packaging in 2026, from budget-friendly mailer boxes to luxury rigid packaging. We include cost factors, minimum order quantities, and tips to get the best value.
Custom Packaging Cost by Box Type
Packaging costs vary significantly based on the type of box, materials used, and order quantity. Here is a breakdown of average per-unit costs based on standard sizes at common order quantities:
Custom Mailer Boxes (Corrugated E-Flute)
Quotable Fact: According to industry data, custom mailer boxes are the most ordered packaging type for e-commerce brands, with average per-unit costs dropping 60–70% when scaling from 100 to 5,000+ units.
A custom mailer box is a one-piece corrugated box made from E-flute cardboard (1.5mm thick) that self-locks without tape, featuring full-color printing on interior and exterior surfaces. Mailer boxes are the most popular custom packaging type for e-commerce, subscription, and direct-to-consumer brands.
| Order Quantity | Price Per Unit | Savings vs 100 Units |
|---|---|---|
| 100 units | $2.50–$4.50 | — |
| 500 units | $1.25–$2.75 | 38–50% |
| 1,000 units | $0.85–$2.00 | 56–66% |
| 5,000+ units | $0.50–$1.50 | 67–80% |
Standard sizes like 10×8×3 inches typically cost less than custom die-cut shapes. Full-color CMYK printing is standard; Pantone (PMS) spot colors may have a small surcharge of $50–$100 per color.
Custom Rigid Boxes (Setup Boxes)
Quotable Fact: Rigid boxes account for an estimated 15–20% of the premium packaging market and are the standard for luxury brands in cosmetics, jewelry, and electronics (Euromonitor International, 2024).
A rigid box (also called a setup box) is premium packaging made from thick greyboard (typically 1,200–2,000 GSM) wrapped in printed paper or specialty materials. Unlike folding cartons, rigid boxes cannot be flattened — they maintain their shape permanently.
| Order Quantity | Price Per Unit | Savings vs 100 Units |
|---|---|---|
| 100 units | $8.00–$15.00+ | — |
| 500 units | $5.00–$10.00 | 33–38% |
| 1,000 units | $3.50–$8.00 | 47–56% |
| 5,000+ units | $2.50–$6.00 | 60–69% |
Stand-Up Pouches
A stand-up pouch (also called a doypack) is a flexible packaging format made from laminated barrier films that stands upright on shelves. Stand-up pouches are the fastest-growing packaging format globally, with the market reaching $35.4 billion in 2024 (Grand View Research).
| Order Quantity | Price Per Unit |
|---|---|
| 500 units | $0.60–$1.50 |
| 1,000 units | $0.45–$1.20 |
| 5,000+ units | $0.25–$0.85 |
Folding Cartons
A folding carton is a thin paperboard box (typically 300–600 GSM SBS or kraft) that ships flat and is folded into shape during packaging. Folding cartons account for approximately 34% of the global packaging market (Freedonia Group, 2024).
| Order Quantity | Price Per Unit |
|---|---|
| 500 units | $0.50–$1.75 |
| 1,000 units | $0.35–$1.25 |
| 5,000+ units | $0.20–$0.80 |
Custom Labels and Stickers
| Order Quantity | Standard Labels | Smart Labels (NFC/QR) |
|---|---|---|
| 500 units | $0.08–$0.25 | $0.50–$2.00 |
| 1,000 units | $0.05–$0.18 | $0.35–$1.50 |
| 5,000+ units | $0.03–$0.12 | $0.20–$1.00 |
What Affects Custom Packaging Cost? (7 Key Factors)
1. Order Quantity — The Biggest Factor
Key Insight: Order quantity has the single largest impact on per-unit packaging cost. Per-unit price typically decreases by 30–50% when increasing from 100 to 1,000 units, and by 60–80% at 5,000+ units.
Most custom packaging manufacturers require a minimum order quantity (MOQ), which ranges from 50 to 5,000+ units. At Cubit Packaging, minimum order quantities start at just 100 units for most box types — significantly lower than the industry average MOQ of 500–1,000 units.
2. Material Selection
| Material | Relative Cost | Best For |
|---|---|---|
| E-Flute Corrugated | $ (lowest) | Mailer boxes, shipping |
| B-Flute Corrugated | $$ (+10–20%) | Heavier products, stacking |
| SBS Paperboard (C1S/C2S) | $$ | Premium folding cartons |
| Kraft Paperboard | $$ | Eco-friendly packaging |
| Rigid Greyboard (1200+ GSM) | $$$$ | Luxury boxes |
| Mylar/Barrier Films | $$–$$$ | Flexible pouches, bags |
3. Box Size and Structural Complexity
Larger boxes use more material. Complex structures like drawer boxes, magnetic closure boxes, or die-cut windows require custom tooling (typically $150–$500 one-time cost).
4. Printing Method
| Method | Setup Cost | Best For | Per-Unit Cost at Scale |
|---|---|---|---|
| Digital Printing | $0 | Under 500 units | Higher per unit |
| Offset Lithography | $100–$300/color | 1,000+ units | Lowest per unit |
| Flexographic | $200–$500/color | 5,000+ units | Lowest for high volume |
5. Finishing Options
| Finish | Added Cost Per Unit | Effect |
|---|---|---|
| Matte/Gloss Lamination | $0.05–$0.15 | Protects print, adds sheen or soft texture |
| Spot UV Coating | $0.10–$0.30 | Glossy highlight areas on matte background |
| Foil Stamping (gold/silver) | $0.15–$0.50 | Metallic accents for luxury feel |
| Embossing/Debossing | $0.10–$0.35 | Raised or pressed texture |
| Soft-Touch Lamination | $0.08–$0.20 | Velvety premium texture |
6. Packaging Design Complexity
Simple one-color designs on kraft are cheapest. Full-color, double-sided printing with multiple finishes costs more but delivers higher brand impact.
7. Shipping and Logistics
Domestic shipping within the US typically adds $0.05–$0.20 per unit. International manufacturing (common in the industry) may offer lower base prices but higher shipping costs and longer lead times of 4–6 weeks.
How to Reduce Custom Packaging Costs
- Order in larger quantities. Going from 250 to 500 units saves 20–30%. From 500 to 1,000 saves another 15–25%.
- Choose standard sizes. Custom die-cuts require tooling. Standard dimensions are cheaper.
- Simplify your design. Fewer Pantone colors reduce offset printing costs.
- Use E-flute for non-luxury items. The most affordable rigid packaging material.
- Combine finishing options strategically. Foil stamp only the logo, not full coverage.
- Use a packaging platform. Platforms like Cubit Packaging integrate design, quoting, and production — eliminating broker markups that add 15–30% to costs.
Frequently Asked Questions
What is the minimum order quantity for custom packaging?
Minimum order quantities vary by manufacturer. Traditional factories require 1,000–5,000 units. Modern packaging platforms like Cubit Packaging offer MOQs as low as 100 units, making custom packaging accessible for startups, small businesses, and product launches.
How long does custom packaging production take?
Standard production takes 10–14 business days after artwork approval. Rush production of 5–7 business days is available at most manufacturers for a 15–25% premium. The total timeline from initial design to delivery is typically 3–4 weeks.
Is custom packaging worth the investment for small brands?
According to Dotcom Distribution's 2024 Packaging Study, 40% of online consumers are more likely to make repeat purchases from brands with premium packaging. For brands selling products above $20, the ROI on custom packaging typically exceeds the cost within 6–12 months through higher customer retention and social media exposure.
Does eco-friendly packaging cost more?
Sustainable materials like recyclable kraft, FSC-certified paper, and compostable films cost 10–20% more than conventional materials. However, a Nielsen (2023) survey found that 73% of millennials will pay more for sustainable packaging, and eco-certifications can open retail channels that require sustainability commitments.
Can I get a sample before ordering in bulk?
Most reputable manufacturers offer physical samples or digital mockups before full production. At Cubit Packaging, we provide free design support, 3D digital proof approval, and physical samples for evaluation before any production commitment.
Get Your Custom Packaging Quote
Ready to get exact pricing for your project? At Cubit Packaging, we offer transparent pricing with no hidden fees — from 100 to 100,000+ units. Use our instant quote tool or speak with a packaging expert today.