Custom Plastic Packaging

Key Takeaways

  • Clear plastic packaging is normally specified in one of three materials: PET, PVC or PP, and they differ in clarity, stiffness and how they take a fold.
  • iBox Factory produces custom plastic packaging from a minimum of 100 units, from about $0.48 per unit at bulk volumes, confirmed on your written quote.
  • Plastic boxes are branded three ways: printed directly on the sheet before cutting, screen printed or foiled after forming, or wrapped with a printed paper sleeve.
  • Production runs from about 7 business days plus 2 to 5 days for delivery, and specialty imported plastic constructions can run up to about 12 weeks.

Plastic packaging is chosen for one reason above all others: the customer can see the product without opening anything. That advantage comes with a tradeoff, since a clear box shows every fingerprint, scuff and misaligned insert. Material choice and branding method are where the decisions sit.

The three common clear materials

MaterialClarity and feelBehavior
PETHigh clarity, crisp and glassyHolds a fold well, resists cracking at creases, the usual default for retail
PVCHigh clarity, slightly softerCreases and crimps easily, widely used for low cost folding boxes
PPSofter, often frosted rather than water clearFlexible and matte in feel, tolerates repeated opening

Frosted and tinted finishes are available in all three, and they hide contents partially, which is useful when the product itself is not the hero.

Getting your brand onto a clear box

  1. Print on the flat sheet before die cutting. This gives you registered, full-coverage artwork and is the route for high volume retail work.
  2. Screen print or foil stamp after forming. Best for a logo or a short line of type in one or two colors, and it looks deliberate on a clear panel.
  3. Wrap the clear box with a printed paper sleeve. The cheapest way to carry full color artwork, and you can change the sleeve seasonally while the box stays the same.

Whichever route you take, leave clear windows genuinely clear. Artwork that creeps across the viewing area is the most common reason a clear box stops doing its one job.

Structures

Plastic folding boxes come as tuck end cartons, crash lock bases for heavier contents, hinged clamshells and two piece lid and base sets. Hang tabs and euro slots can be built into the die for peg display, and inner trays can be die cut from the same material or from board. The die is included on iBox orders, so the structure is built around your product rather than the other way around.

Handling, dust and scratches

Clear material shows everything. Scratches picked up in transit, dust that settles during hand packing, and fingerprints from filling all read as damage on a clear box even though the product is untouched. Plan for it: keep the protective interleaving on until the box is filled, brief your packing team to handle boxes by the edges, and consider a frosted or tinted finish if your fill process is manual and fast.

Where plastic is the wrong answer

  • If the product needs to be shipped alone in the mail, a clear box is not a mailer. Put it in a corrugated outer.
  • If your brand is built on an uncoated, natural look, a paper structure will do more for you. See kraft boxes.
  • If the artwork carries a lot of copy, printing it on a clear panel reduces legibility. A sleeve solves that.

Minimum, price and turnaround

The minimum is 100 units. Unit pricing starts at about $0.48 per unit at bulk volumes and is confirmed on your written quote, because plastic pricing moves on material, gauge and size. US shipping, design support and a digital proof are included.

Turnaround is stated per product in three lanes: Rush (expedited production plus air freight), Standard (air) and Cost saver (sea). Production runs from about 7 business days plus 2 to 5 days for delivery, and specialty imported constructions can reach about 12 weeks.

Quote your plastic packaging

Send product dimensions, material preference and quantity through the quote form. Related: window boxes if a board box with a clear panel would also work, and sleeve boxes for the printed wrap route.

Get a Custom Quote

Free die and plates, free design support, free US shipping. Minimums from 100 boxes.