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Custom Packaging

Custom Packaging Made Around Your Product

From the structure and material through to printing, finishing and ongoing production, Pakko helps Australian businesses create cardboard packaging that is practical, protective and ready to manufacture.

Whether you already know the box style and dimensions or need help developing the right solution, our Brisbane team can guide you through the next step.

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Designed, printed and manufactured in Brisbane.
Studio photo — printed mailer box, folding carton and corrugated shipping carton with insert, side by side

Choose the Right Way to Start

Every packaging project begins differently. Select the pathway that best reflects where you are now.

Photo — product being test-fitted into a prototype insert, measurement or structural development in progress
Practical packaging development

The Box Should Fit More Than the Product

Custom packaging is not only about placing a logo on a standard box. The structure needs to work with the product, the way it is packed, how it will be transported and how often it will be ordered.

Before recommending a solution, we consider the full journey of the packaging.

Product dimensions and weight
Protection during transport
Internal inserts and product placement
Packing and assembly time
Branding and presentation
Shelf, storage and pallet efficiency
Production quantity
Repeat-order requirements

The result is packaging developed around how your business will actually use it.

What we manufacture

Custom Packaging for Different Products and Applications

Pakko manufactures cardboard packaging across a range of structures, materials and production quantities. Your packaging can be made to a custom size, printed to suit your brand and developed with inserts or finishes where required.

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From idea to production

How Custom Packaging Works

The exact process depends on the complexity of the packaging, but most custom projects move through five clear stages.

01

Share Your Requirements

Tell us about the product, dimensions, quantity, printing, delivery location and how the packaging will be used.

02

Confirm the Structure and Material

We help determine the packaging style, board grade, internal fit and production method suited to the project.

03

Develop and Test

Where required, a structural design or plain sample is created so that fit, assembly and presentation can be reviewed before production.

04

Approve the Artwork

Artwork is applied to the approved packaging keyline and checked before final production approval.

05

Manufacture and Deliver

Once approved, the packaging moves into production at our Brisbane facility and is prepared for collection or delivery.

Some straightforward projects can begin from an existing keyline or confirmed dimensions. More complex inserts and structural packaging may require physical products for accurate development and testing.

Test before production

Understand What Is Being Developed

A structural design, plain sample and printed production sample serve different purposes. We will advise which stage is appropriate based on the packaging complexity and the level of testing required.

Structural Packaging Development

Structural development is used when a packaging solution needs to be designed around a physical product, internal layout or specific functional requirement.

This may include:

Creating a new packaging structure
Developing an internal insert
Testing product fit and placement
Reviewing structural integrity
Improving assembly or presentation
Preparing the final manufacturing keyline

For product-specific structures, we may need the physical products to test fit and performance accurately.

Samples and Prototypes

Samples allow you to review the packaging before the main production run.

Depending on the project, this may include:

A plain material sample
A custom-sized structural prototype
A digitally printed sample
A sample made from the intended production material
An existing stock sample for material reference

Your Pakko contact will explain what the sample can and cannot confirm before you proceed.

Sample pricing and availability depend on the structure, material, printing method and level of development required.Design & Artwork Guide
Print and finish

Make the Packaging Look and Feel Like Your Brand

Once the structure is established, printing and finishing can be selected to suit the design, material, quantity and budget.

Pakko can help determine the most practical production method rather than applying the same printing process to every project.

Digital Printing

Well suited to short runs, prototypes, multiple artworks and full-colour custom packaging.

Offset Printing

Suited to high-quality printed sheets and detailed artwork that can be laminated to corrugated board.

Flexographic Printing

A practical option for larger runs and simpler artwork applied directly to corrugated packaging.

CMYK and Specified Colours

Projects may use full-colour CMYK printing or specified colours depending on the print process and artwork requirements.

Finishing options
FoilingEmbossing and debossingGloss or matte celloglazingPrinted sleevesDie-cut windowsSpecialty stocks and board finishes
Photo — printed corrugated board
Photo — foil detail
Photo — emboss detail
Photo — kraft board finish
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Packaging that can grow with you

Start with What You Need Now

Your first packaging order does not need to predict every future requirement. Pakko can support an initial product launch or short-run project, then help establish a repeatable manufacturing pathway as demand grows.

Launch and Test

Create an initial quantity to test the product, structure, artwork and customer response.

Repeat and Refine

Reorder an approved design, review quantities and improve production efficiency as demand becomes clearer.

Plan Ongoing Supply

For established requirements, discuss multiple SKUs, volume pricing, forecasts, scheduled production and drawdown arrangements.

The objective is not simply to manufacture the first order. It is to establish packaging that can continue working as the business changes.

Pakko team member discussing a custom packaging enquiry with a customer
Manufactured locally

One Team from Product Development to Production

Pakko brings packaging guidance, design support and manufacturing together through one Brisbane-based team.

This gives customers a direct point of contact throughout the project and creates a clearer path from the first discussion through to repeat production.

Direct local accountabilityPractical packaging guidanceFlexible manufacturingSupport beyond the first order
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What to Send Us for More Accurate Pricing

You do not need to have every detail finalised. However, the more information you can provide, the more accurately we can assess the project and recommend the right next step.

Product description
Product dimensions and weight
Required packaging quantity
Preferred box style, if known
Internal and external dimensions, if available
Printing and finishing requirements
Delivery location
Required timing
Existing artwork, samples or reference images
Photographs or physical samples of the product

For custom inserts and product-specific structural designs, physical products may be required before the final structure can be developed.

Prepare Your Custom Quote
Pakko team reviewing a structural packaging sample on the production floor

Custom Packaging Questions

Is there a minimum order quantity?

Minimum quantities depend on the packaging style, material, printing method and manufacturing process. Some products can be produced in short runs, while other methods become more practical at larger quantities.

How long does custom packaging take?

Timing depends on structural development, artwork approval, material availability, printing method and the current production schedule. Your Pakko contact will confirm the expected timeframe for your project.

Do I need finished artwork before requesting a quote?

No. You can begin with dimensions, quantities and a description of the packaging. Artwork can be prepared once the structure and keyline have been confirmed.

Can Pakko design an insert around my product?

Yes. Product-specific inserts can be structurally developed to support fit, placement and protection. Physical products may be required for accurate testing.

Can I see a sample before production?

Sample options depend on the project. These may include a plain sample, structural prototype, digitally printed sample or existing material sample.

Can you manufacture repeat orders?

Yes. Once a design and specification have been approved, Pakko can manufacture repeat orders and discuss ongoing supply arrangements for established requirements.

Can I use my own packaging design?

Yes. Existing keylines and packaging designs can be reviewed to determine whether they are suitable for Pakko's materials and manufacturing processes.

What information is needed for a quote?

The most helpful information includes the box style, dimensions, quantity, product details, printing requirements, delivery location and any artwork or reference files.

Ready to Start Your Custom Packaging Project?

Share what you are packaging, the quantity you need and where you are in the process. We will help identify the most practical way to move forward.

Get a Custom Quote

Already know the size and box style? Design and Price Online