How Fast Can You Get Custom Packaging? Rush Order Timelines Explained
Key Takeaways
- Custom labels and stickers can be rush-produced in 2-3 business days with digital printing — the fastest rush turnaround available
- Mailer boxes and folding cartons take 3-5 business days on rush — digital CMYK printing eliminates plate setup delays
- Mylar bags, stand-up pouches, and rigid boxes require 5-7 business days because flexible packaging has additional lamination and curing steps
- Rush premiums range from 15% to 60% above standard pricing depending on format and how tight the timeline is
- Rush minimums match standard minimums — 100 units for boxes, 250 for labels, 500 for pouches — no increases
The Moment You Realize You Need Packaging Fast
It usually starts with a phone call or a panicked Slack message.
Your manufacturer shipped early. Your current packaging vendor just pushed your delivery date back two weeks. Or maybe you landed a retail placement you were not expecting, and now you need shelf-ready packaging by the 15th.
Whatever the reason, you are here because you need custom packaging faster than the standard 10-14 day timeline. And the good news is: you have options.
We process rush orders every single week at Cubit — for product launches, trade shows, seasonal inventory, and the occasional supplier failure. This guide lays out exactly what is possible, what it costs, and how to get the fastest turnaround.
Rush Production Timelines by Packaging Type
Every timeline below is measured from the moment you approve your digital proof to the day your order ships. Your proof arrives within 15 minutes of submitting your specs — that part is instant.
| Packaging Type | Rush Timeline | Standard Timeline | Time Saved |
|---|---|---|---|
| Labels & Stickers | 2-3 days | 5-7 days | 3-4 days |
| Mailer Boxes | 3-5 days | 10-14 days | 7-9 days |
| Folding Cartons | 3-5 days | 10-14 days | 7-9 days |
| Corrugated Boxes | 3-5 days | 7-10 days | 4-5 days |
| Gable Boxes | 3-5 days | 7-10 days | 4-5 days |
| Poly Mailers | 3-5 days | 7-10 days | 4-5 days |
| Mylar Bags | 5-7 days | 10-14 days | 5-7 days |
| Stand-Up Pouches | 5-7 days | 10-14 days | 5-7 days |
| Rigid Boxes | 5-7 days | 12-15 days | 7-8 days |
| Paper Bags | 5-7 days | 10-14 days | 5-7 days |
According to Cubit's production data from 2025: 94% of rush orders ship on time or early. The remaining 6% ship within one business day of the quoted deadline — usually due to artwork revision delays on the customer side, not production.
Why Some Formats Are Faster Than Others
If you are wondering why labels take 2 days and mylar bags take 5, it comes down to manufacturing steps.
Labels and stickers are the simplest. Digital print on adhesive stock, die-cut, roll or sheet. Two steps, done.
Mailer boxes and folding cartons need digital print on corrugated or SBS board, die-cutting, scoring, folding, and gluing. More steps, but all happen in the same facility.
Mylar bags and stand-up pouches are the most complex. Print on film, laminate multiple layers together, cure the adhesive (this alone can take 24 hours), then pouch-make on a separate machine. You cannot shortcut the curing time without compromising the barrier properties that make mylar bags work.
What Printing Works Best for Rush Orders?
Digital printing is the obvious winner for rush timelines. Here is why:
| Factor | Digital (CMYK) | Flexographic | Offset/Gravure |
|---|---|---|---|
| Setup time | None | 2-4 hours | 4-8 hours |
| Plate/cylinder cost | $0 | $150-$400 | $200+/color |
| Minimum run | 100 units | 1,000+ units | 2,500+ units |
| Color accuracy | Excellent | Good | Excellent |
| Rush-friendly? | Yes | Possible (5-7 days) | No |
Digital printing has zero setup time because there are no plates or cylinders to produce. Your file goes from PDF to press in minutes. That alone shaves 1-2 days off the timeline compared to flexo or offset.
For rush orders specifically, digital is almost always the right call unless you are ordering 5,000+ units.
How Rush Pricing Works
Let us be upfront about costs. Rush production costs more than standard because your order jumps the queue and requires overtime scheduling.
| Rush Timeline | Typical Premium |
|---|---|
| 5-7 day rush | 15-25% above standard |
| 3-5 day rush | 25-40% above standard |
| 2-3 day rush (labels only) | 40-60% above standard |
Real example: A standard order of 500 custom mailer boxes (10×8×4", kraft, full-color digital) costs approximately $2.50/unit. The same order on a 3-5 day rush timeline costs roughly $3.25-$3.50/unit. That is a $375-$500 premium on the total order — meaningful, but usually worth it when the alternative is missing your deadline.
Shipping is separate. Standard ground shipping (3-5 transit days) is included free. If you need the boxes sooner than that, FedEx 2-Day adds $75-$200 depending on order size, and overnight adds $150-$400.
The Four-Step Rush Process
Here is exactly what happens when you place a rush order with Cubit:
Step 1: Submit Your Specs (5 minutes)
Use the rush quote form or the rush order button on our site. Tell us what you need, how many, and your deadline. Include your artwork if you have it.
Step 2: Get Your Quote and Proof (15 minutes)
During business hours, you will receive pricing and a 3D digital mockup within 15 minutes. This is not a rough estimate — it is your actual price with the rush premium included.
Step 3: Approve and We Start Immediately
Once you approve the proof and pay, your order goes directly into production. No queue. No waiting. Digital files hit the press the same day.
Step 4: Ship and Track
When production finishes, your order ships with tracking. Standard ground is included. Expedited shipping is available if your deadline requires it.
When Rush Orders Make Sense (and When They Do Not)
Rush makes sense when:
- Your product launch date is fixed and cannot move
- A trade show or event is approaching and you need branded packaging for your booth
- Your current supplier failed to deliver and you need a backup
- Seasonal inventory (holiday, Valentine's Day, 4/20) needs packaging NOW
- You are rebranding and need updated packaging before a media feature
Rush does NOT make sense when:
- You can plan 2-3 weeks ahead — standard production saves you 15-40%
- Your artwork is not finalized — every revision adds time
- You need complex finishes (foil stamping, embossing, spot UV) — these require 7-10 days minimum even on rush
- You are ordering 10,000+ units — large runs physically cannot be compressed into 3 days
Expert tip from the Cubit production team: "The biggest delay on rush orders is not our production — it is artwork revisions. If you can submit print-ready files (300 DPI, CMYK, with bleed), we can start printing within hours of your approval. If we need to design or revise your artwork, add 1-2 days to the timeline."
Common Rush Order Questions
How fast can I get custom packaging with rush production?
The fastest rush turnaround is 2-3 business days for labels and stickers with digital printing. Most box formats — including mailer boxes, folding cartons, and corrugated boxes — can be produced in 3-5 business days. Flexible packaging like mylar bags and stand-up pouches typically need 5-7 days for rush orders.
What is the minimum order for rush packaging?
Rush minimums match standard minimums at Cubit: 100 units for most box types, 500 for mylar bags and stand-up pouches, and 250 for labels and stickers. We do not increase minimums for rush orders.
How much does rush packaging cost compared to standard?
Rush premiums range from 15% to 60% above standard pricing depending on the packaging format and timeline. A 5-7 day rush on mylar bags adds 15-25%. A 3-5 day rush on mailer boxes adds 25-40%. Same-week delivery on labels adds 40-60%.
Can I get food-safe packaging on a rush timeline?
Yes. All rush food packaging from Cubit uses the same FDA-compliant, food-grade materials as standard production. This includes BPA-free mylar, food-safe kraft pouches with PE liners, and FDA-approved inks. We stock food-grade substrates specifically to avoid sourcing delays.
What if I need packaging for a product launch next week?
Contact us immediately through the rush order form or call (510) 203-8855. For launches under 7 days out, we recommend digital-printed mailer boxes (3-5 day production) with expedited shipping for the tightest windows.
Do rush orders include free shipping?
Standard ground shipping is included with all rush orders. For same-week delivery, expedited shipping (FedEx 2-Day or overnight) is available at an additional cost. Ground shipping adds 3-5 transit days on top of production time.
Need custom packaging fast? Submit a rush quote and get pricing within 15 minutes. Or visit our rush order page to see all available formats and timelines.