Factors to Consider When Choosing Material and Carton Type for Packaging

You know that packaging is a powerful tool that protects products, enhances the customer experience, and drives sales – but how can you choose the perfect packaging for your unique needs?

This guide lists five critical factors to consider when choosing packaging materials and folding carton types so you can make an informed decision that helps maximize your packaging ROI.

1. Cost

Cost is always an important factor, and it’s critical to evaluate both material pricing and product efficiency – in other words, how your choice of packaging can impact costs post-production.

Consider these packaging cost factors:

• Material price: Some materials are more expensive than others, but the cost could be justified if your application calls for premium packaging for high-end or luxury products
• Assembly time: Rapid assembly folding cartons allow for faster filling, while cheaper folding cartons require more time to fill and can increase labor costs. For example, auto-lock bottoms require less time to assemble, cutting overall costs
• Shipping and storage: Cartons that ship flat take up less space and can be more cost-effective to transport

Be sure to evaluate the overall cost of your packaging choices, not just the initial unit cost.

2. Sustainability

Sustainability is important for many businesses and consumers, so consider packaging that’s made from recycled materials and is recyclable itself, biodegradable, and/or compostable.

In many cases, consumers expect packaging that not only meets sustainability goals, but also looks and feels eco-friendly. Color, texture, and printed statements such as “made from 80% post-consumer recycled content” can enhance the sustainable look of your packaging.

3. Product Protection and Durability

Delicate products and heavier items require strong, durable packaging that protects the contents inside. Snap lock cartons are good for heavy items, for example, and auto-lock bottoms are even stronger.

Material thickness is another important consideration. A 14- or 16-point material may not be a good option for heavier items like glass candle jars, but an 18- or 20-point (or thicker) material should tackle the extra heft.

Pharmaceutical and other health-related products often call for tamper-evident packaging. Yours can feature locking mechanisms and tabs to keep folding cartons from popping open.

If you’re packaging frozen or refrigerated food items, it’s a good idea to choose coated substrates that offer moisture resistance.

4. Brand Presentation and Consumer Experience

Packaging is a crucial element of brand identity and the overall consumer experience. The right packaging material and design communicates ideals such as luxury, sustainability, and fun while aligning with brand values.

• Visual appeal: SBS offers the best printing surface for high-quality graphics, so it’s perfect for luxury goods, cosmetics, and high-end food packaging
• Sustainability: CNK and CRB look more natural, and CRB is the most sustainable option as it’s made from post-consumer recycled content
• User experience: Pillow packs and stay flats offer unique, engaging unboxing experiences (for example, pillow packs are fun to pop open, and stay flats can feature interactive openings)

It’s also vital to consider brand and color consistency when choosing packaging materials and folding carton types. Color production can vary across different substrates, such as paper and plastic, and when applied with different printing processes, such as flexography and lithography.

Identify where your packaging will be displayed and whether it needs to match other packaging placed next to it, then ask your packaging partner to assist with color matching for a consistent brand experience.

5. Functionality and Ease of Use

Finally, don’t overlook carton functionality and ease of assembly. For example, straight tuck end and reverse tuck end cartons are easy to assemble. Auto-lock bottom cartons are even faster.

Consider whether you’ll be filling your cartons manually or automatically. If you’re doing lower volumes like 1,000 or 5,000 boxes, a snap lock could work, but if you’re doing higher volumes, auto-lock bottoms would be best for hand assembly.

It’s also a good idea to think about shelf readiness and product accessibility. Auto-lock bottom and snap lock cartons are sturdy and stackable, for example, while pillow packs and stay flats are visually appealing and easy to open.

If you’re not sure which type of carton or packaging material is right for your project – or you simply have questions – Priority Packaging is here to help. Our experts will work with you to balance the factors listed here and identify the perfect packaging solution for your unique needs.