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How Rigid Boxes are Manufactured?

Published on: 28 Jul, 2022
How Rigid Boxes are Manufactured?

Rigid Boxes or setup boxes are the most common type of packaging carton. They are specifically used in the packaging of high-end and premium products that require top-quality presentation and utmost protection. Brands consider these luxurious boxes to package their products which gives them a remarkable and significant appearance. These boxes aid a specific product to stand out in the market and grab the maximum attention of onlookers. As no one can resist an item with exceptional packaging and it compels people to know more about that product. As the presentation of items is considered to be the main component that determines the success of a particular brand. So by the utilization of these custom packaging boxes, any brand can effectively uplift the overall appearance of their items which will result in maximum sales of products and in the generation of great revenues.

Manufacturing Processes

Brands opt for a variety of these setup boxes for different types of products. These boxes are available in abundant shapes and styles that retailers can use according to the requirements of their products.

These boxes are manufactured from sheets of chipboard (graybeard or plain board). They go through the processes of cutting and slashing and then these chipboard sheets are modified into the required shape and size of rigid boxes or set-up boxes. A specialty decorative paper is also wrapped around these boxes which effectively uplifts the overall outlook of these boxes. Some manufacturers make these boxes through machines and some get them prepared through handmade procedures. The strength of the paper that is wrapped around these boxes varies for different types of boxes. In some boxes, the decorative paper is tightly wrapped and in some boxes, this paper is loosely attached which further enhances the look of these boxes by making them look luxurious.


The first step involved in the manufacturing of these boxes is sizing. These boxes are made from sheets of chipboard which are slashed and cut in accordance with the size of the product that will be placed in these boxes. The exact sizing of these boxes is very crucial. These boxes should be made according to the required size of products that will be packaged in them. The exact size of the packaging according to the size of the items makes them more appealing and striking.

These boxes are made from chipboard or paperboard which is approximately 2 to 3 mm thick. As the name depicts, these boxes are not folded flat when they are shipped over larger distances and are remained intact or erect, in their perfect shape while conveying a sense of luxury, elegance, and prestige.


After sizing these boxes the next step is folding. The material involved in the packaging of these boxes is collapsible and these boxes are assembled conveniently. In the folding process, the sides of the box are secured up to create the base shape. After these boxes are folded, we have the basic skeleton for our packaging. As these boxes come in a variety of types, the folding mechanisms slightly differ in each type. In the partial finish boxes, the cardboard is completely visible from the outside while in full finish boxes the cardboard is covered by using a decorative wrap. These boxes are extremely enduring and resistant and are folded and manufactured for a vast range of products available in the market.


This is a very important step in the manufacturing processes of these setup boxes. As these setup boxes efficaciously uplift the outlook of the products packaged in them, they should be printed with the most striking yet sophisticated designs that will help the products to get noticed by customers. The printing is done on a piece of wrap paper and other processes such as lamination and embossing are also done on these decorative papers. These wraps are then glued to the shape of these setup boxes.


This is the last and final step in the manufacturing of these packaging boxes. These wraps are attached to these boxes and at last, bring these rigid boxes to life. The extent of wrapping the specialty decorative papers around these boxes varies in different types of boxes. For example, in the partial finish boxes, these wraps are loosely attached to these boxes and the cardboard is visible while in the full finish boxes, these decorative papers are tightly wrapped around the overall structure of these boxes, making the cardboard not visible from the outside. These boxes are used to package expensive and luxurious items like jewelry, watches or smartphones, etc. as they provide maximum protection. Online brands also prefer these boxes because of their durability and ship items all over the world.

Material Involved in the Preparation of Rigid Boxes

  • Chipboard
  • Paperboard
  • Corrugated Board
  • Polystyrene Foam
  • Foam core
  • Plastic sheeting

Chipboard is Considered to be the Best Manufacturing Material

Although there is a wide range of materials that can be utilized in the manufacturing of rigid boxes but most brand owners opt for chipboard material because of being more resistant and bearable. This material can easily sustain under pressure and stress. Chipboard is made from a bio-degradable and recyclable material and does not exert any negative impacts on our environment. Moreover, chipboard contains multiple layers of sustainable paper which makes it a thick packaging material and can conveniently bear substances of relatively higher weight. When brand owners have to package higher-quality, luxury items, they prefer chipboard because cardboard or paperboard can prove to be susceptible to water and cannot match the standard of high-end products.

Furthermore, chipboard is lighter in weight than cardboard which makes it an ideal material for shipping. As it costs less to be shipped to farther distances because of being light in weight.

Polystyrene is the Most Preferred Interior Material for Rigid Boxes

Polystyrene is considered best for the interior of these rigid boxes as it can efficaciously protect fragile items and helps their quality to remain intact and maintained when these products are transferred over larger distances. Polystyrene can protect every angle of the product by creating a durable and sturdy interior structure.

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