Inside Sustainable and Branded Packaging

Industry News and Perspectives

09 Jul 2015 Mailer Envelope Options for Reducing Cost

Every form of mailer envelope plain or printedAs we often like to say, sometimes the best box for shipping a product is not a box at all. In some cases a mailer envelope will satisfy the need, at minimal cost per container, for shipping and for processing.

We offer a variety of stock (unprinted) and custom printed mailer envelope options including:

Plastic Mailer Envelope Options – still a favorite for some customers because of their light shipping weight and moisture resistance.

Unpadded – very popular for clothing and other soft goods. We have two different grades available and can be seen at this link. The minimum for custom printing is 25,000 envelopes.

Padded or “bubble lined” – ideal when the profile is low and a little protection is needed. Available (unprinted) stock sizes can be seen here and custom printing has a minimum of 25,000 envelopes.

Paper Mailer Envelope Options – the clear choice for most eco minded shippers and consumers.

Unpadded – available in white or Kraft, unprinted stock sizes and can also be custom printed in a VERY low, one case minimum. The low cost, low minimum branding option has quickly become a favorite for shipping tee shirts and other apparel.

Padded – Eight different unprinted sizes in stock but no longer available custom printed. Even though it is considered a green product (100% paper), the weight can make it costly to ship.

Rigid mailers – the perfect solution for mailing documents and other very low profile products. We have eight unprinted sizes in stock and the minimum for custom printing is 25,000 envelopes.

Paper/Poly Mailer Envelopes – these are not a stock item and not recyclable because the exterior is paper and the interior is plastic bubble, yet they are lightweight and preferred by people who want or need a paper exterior but also need some cushioning. These are available ONLY in custom printing with a minimum of 25,000.

Which mailer envelope is best for you?

We will be glad to review your application and help you determine that. The answer usually depends on what you are shipping, how you are shipping it and the order quantity. Some low cost solutions are only available in larger quantities, and of course, custom printing and branding can also be an important factor.

Please call us at 630-551-1700 or contact us at Globe Guard for unprinted stock products and Salazar for custom printed applications. Someone from our customer support team can help you decide which product is best for your specific needs.

Related posts:

Read More

19 Jun 2015 Four New Die Cut Mailer Box Sizes Available and on Sale!

10 X 8.5 X 4 lock front B-flute mailerWe are very pleased to announce the addition of four new corrugated mailer boxes to the list of stock boxes on our green packaging store –

What is the difference between a die cut mailer and a standard RSC shipping box?

An RSC (regular slotted container) box most commonly used has four flaps on top and four flaps on the bottom, and is sealed using two pieces of tape. A die cut mailer has a hinged lid that allows it to open like a cigar box and can be tuck top or front lock in design for a little extra security. We refer to the die cut mailer as more of a presentation box because it is typically more attractive and easier to open, making it ideal for subscription and e-commerce applications.

If your focus is custom printed, branded boxes, why are you adding more unprinted sizes to your inventory?

There are really several good reasons including:

  1. Not all of our customers are ready for branded packaging because of order minimums (1,000 boxes) or perhaps because of size uncertainty.
  2. Even large volume, custom print customers occasionally have a need for a different (unprinted) size for a particular product or promotion.
  3. Art is being developed or a rebranding is anticipated
  4. Starting off with a stock, unprinted size permits a smoother transition into custom printed boxes later.

The four new sizes of die cut mailer boxes

5x4x35” X 4” X 3” lock front, B-flute mailer– this is more of a reintroduction because it was a stock item and was eliminated due to sluggish sales. More recently we have been overwhelmed by inquiries from jewelry, e-juice and other people looking for a small, secure mailer box. Keep in mind, it can be custom printed in a low 1,000 box minimum.

8.75 x 5.75 x 2.75  E-flute stock mailer8-3/4” X 5-3/4” X 2-3/4”  lock front, E-flute mailer – E-flute is thinner, providing a more retail, less industrial look for our customers who want a more attractive presentation box. This new size ships well and is ideal for anything from snacks to cosmetics.

10” X 8-1/2” X 4” – (shown above) lock front, B-flute mailer – This box was added for everyone looking for something “just a little smaller” than our very popular 12-1/4” X 9-1/4” X 4” box. Since size matters in the new “dimensional rate” world, it is perfect for pet treats, snacks, and other subscription boxes.

11 x 12x 2 top tuck, E-flute mailer11” X 12” X 2” – top tuck, E-flute mailer – The E-flute makes this box as sharp looking as it is strong. It is the perfect presentation box for retail or e-commerce, especially for apparel such as baby clothes or designer tee shirts.

Let us know if you have any questions on any of these new items or if you would like to see a sample. Pricing and other details are available in the “corrugated mailer” section of our Globe Guard store and please remember, the introductory sale prices are good only through August 31, 2015. .

Related posts:

Read More

11 Jun 2015 Cost Estimates for Custom Printed E-commerce and Subscription Boxes

great looking shippable boxesWe receive a lot of inquiries and most of them are looking for a “ballpark” price for the custom printed mailer box they have in mind. Many callers are in the process of creating their business plan and/or price structure and understandably, want to know what their packaging is going to cost. Here are a few of the most commonly asked questions on this topic:

Can you send me your printed price list?

This is custom work; no two designs and customers are identical so there is no corresponding price list. Life and business would be easier if it were possible, but the info a price list would contain would likely be confusing and possibly inaccurate so we prefer to answer each inquiry individually.

Why don’t you have pricing for a “basic” print?

What is “basic” varies a great deal from one person to another. For example a “basic blue box with white lettering” is a reverse print flood coat and there is nothing “basic” about it. After launching hundreds of custom printed mailer boxes, we know designs tend to get more complex over time, not less. We will often use one standard color on a Kraft exterior as a base line to give people a starting point.

What is the minimum information you need for a price?

For starters we need your box size. Just for the record, there is no medium, standard, or average box size. Since we make them to order, you have an opportunity to choose the best fit.

We also need to know your choice of Kraft (brown) or white board color (inside and outside) and how many colors you want to print inside and/or outside. Of course the quantity you plan to order at this time is also necessary. (Keep our 1,000 MOQ in mind.) For example, a great inquiry would be something like this: 2,000 boxes, printed one color on Kraft outside and two colors on white inside. What you print (logo, web address, etc.) at this point does not matter and has little impact on the price.

How accurate are your ballpark prices?

Our numbers are only as good as the information you provide to us, but in most cases we are within plus/minus 10%. When we estimate cost, we typically provide a range such as “between $1.20 to $1.30 per box” and unless your design specs change dramatically, we are usually within the range provided. There are few surprises at Salazar Packaging!

 What is NOT included?

The shipping cost is almost impossible to estimate until we know what we are shipping and where we are shipping it. The specific delivery requirements at the address provided can make a big difference in the shipping cost. The only other additional cost is the ONETIME print plate cost that typically runs between $400 and $600 per color. Plates are usually less for RSC style boxes at $200 to $300 per color.

What if I need a firm and final quote?

If you provide firm and final art, we can provide you with firm and final pricing. We have learned from experience that box or art descriptions, regardless of how detailed they are, do not tell us everything we have to know. We also have found that artwork tends to evolve and change as a project nears completion. It is our sincere desire to provide you with the most accurate information possible and that is much easier to accomplish when we can actually see your finished artwork.

Our goal is ALWAYS to deliver the best possible box at the lowest possible cost and we are great about providing you with options and alternatives so you are able to make an informed decision.

Please contact us at Salazar Packaging or call us at 630-551-1700. You can also see our branded packaging overview and examples of our work in our gallery. We looking forward to serving you and helping you create your new, branded packaging.

Related posts:

Read More

05 Jun 2015 Globe Guard® E-commerce and Subscription Die Cut Mailer Boxes on Sale!

9-5-5 top tuck mailerWe have a lot of great changes coming soon on our selection of 100% recycled content die cut mailer boxes, and will soon be adding five new e-commerce box sizes to our store. In order to make space, we are reducing inventory on some overstocked items by offering them up to 20% off of our standard, low prices. Here are the boxes that are available on sale through the end of July:

9” X 9” X 5” – a high profile top tuck mailer. It is ideal for everything from candles to snacks.

5-13/16” X 5-3/4” X 1-15/16” – We call this one our 5-5-2 mailer box, though technically it is closer to 6-6-2. It is also a top tuck design and is used often for jewelry and cosmetics.

7-3-2 lock front mailer7-1/2” X 5-1/2” X 4” – This one is unusual because it is an eco mailer style box where the back opens up, making it easy to remove the contents. This is ideal for a box within a box type program.

7” X 3-1/6” X 2-5/16” – Internally we refer to this as our 7x3x2 front lock mailer and it is by far the most popular size we have for eye glass and sunglass shippers. It is also used but e-juice and personal care products.

11” X 12” X 2” – This is an E-flute, top tuck box that delivers more of a retail (less industrial) look. It is still plenty strong and makes a great presentation box for clothing as well as books.

11-12-2, E-flute, top tuck mailer11-1/8” X 8-5/8” X 7/8” high – This unique box is great for everything from books and sheet music to tee-shirts. See this recent post.

Custom Printing Also Available

All five of these boxes and every other stock die cut mailer we offer can be custom printed in a very low, 1,000 box minimum. After helping to create hundreds of beautiful and unique branded e-commerce and subscription boxes, we have made the process easy, and the additional cost for printing, minimal.

If you have any questions or would like to see a sample, please contact us at Globe Guard Products. Custom printed or stock, we would love to be your supplier for e-commerce boxes.

Related posts:

Read More

26 May 2015 Random Repeat Patterns for E-commerce and subscription boxes

9x9x4 printed 2 colors out and 1 color inWe have seen those cool designs for years in/on hand bags, cosmetics and other luxury and high end products. They always create an upscale look and are instantly recognizable, which is really what branding is all about. We have done several new designs incorporating this random repeat look and the most unique, recent one is Express Jet.

Express Jet Selects Salazar Packaging for their new box

You can check out their web site at and you will see they are the world’s largest regional airline. When they decided they need an attractive intro box for their new pilots, we were glad they called us. We were able to use one of our stock cutting dies to save them time and money and the end result is shown in these photos.

Close up of random repeat inside printRandom Repeat Patterns Are Eye Catching

We will print anything anyone wants on their box but I think sometimes shippers spend a great deal of time and energy developing text that is rarely read. I know as a consumer I am eager to get my hands on what is inside the box and I am unlikely to spend a lot of time reading copy, regardless of how cleverly it is written or presented.

Marketing experts tell us we have only a few seconds to capture the attention of the recipient and make a lasting impression. A quick way to accomplish that is with an incredibly unique pattern of a logo, name, or image. We all know images are always easier to remember compared to text or copy so the objective is accomplished.

If you are interested in discussing your custom printed box needs, please feel free to contact Salazar Packaging or call us at 630-551-1700. We will help you create a great looking box, at minimal expense, and do it quickly for you. Most of our first time orders ship within two weeks.

Related posts:

Read More

18 May 2015 Globe Guard® 11-8-1 Mailer – Unique and on sale!

Unprinted or cusotm print in low 1,000 minimumWhat makes this box so unique is the way it can be printed and used in a vertical or a horizontal mode so it can open like a book or like a tray.

The actual inside dimensions are 11-1/8” X 8-5/8” X 1” and it is a stock item on our , green packaging store. Its versatile design has enabled it to be used for shipping everything from catalogs, flooring samples and business forms to tee shirts, photos and award plaques.

It is available in a low one bundle minimum ($30 minimum store purchase) and ships for a low $7.00 flat fee, anywhere in the continental USA.

Outside print ends up insideCustom printing is always an option

The box is designed to be printed on one side of the board and when formed, some of the print ends up inside. That may not sound like much of a difference, but it allows you to place graphics inside the box without the cost of inside printing and the necessary additional print plate. It also enables print to “flow” inside creating endless print options and unique looks.Ideal for shipping books and paper products

On sale 20% off through June 30, 2015

For the next six weeks we are offering the unprinted, stock version of this box on our green packaging store for 20% off of our already low prices. This makes this terrific option the same cost as some mailer envelopes or rigid mailers that may not provide the same level of protection or attractive presentation.

What if the size is not right for your product?

Please let us know what size you need. The beauty of this design is that it can be easily adapted to accommodate much smaller or larger product sizes.

Contact us at Globe Guard Products if you have any questions or if you would like to see a sample.

Related posts:

Read More

11 May 2015 Pooki’s Mahi® – Great Taste and Frustration Free Packaging®

Frustration Free certified E-commerce shipperCongratulations to Pooki’s Mahi for having achieved the prestigious and hard earned certification for Amazon’s “Frustration Free Packaging and E-commerce Packaging.” If you are familiar with the process, you can appreciate the accomplishment.

This designation applies to all 11 Pooki’s Mahi SKU’s for their primary packs as well as their 24 unit shipper which we are proud to produce for them. Not only is it one of the most attractive e-commerce, subscription boxes we have ever created, we now know it can pass this stringent certification for packaging that is eco and consumer friendly.

To learn more about Pooki’s Mahi please visit their web site and FYI, the office staff at Salazar Packaging officially certifies their coffee as “delicious”.

To learn more about Salazar Packaging and our attractive, low cost e-commerce and subscription box capabilities, please check out the related posts below. You can also contact us via email or call us at 630-551-1700.


Press release:

Related posts:

Read More

30 Apr 2015 Reduce Shipping Costs by Using Mailer Envelopes Rather than Boxes

Up to six colors custom printIt may sound a little strange coming from a corrugated box designer and supplier but the “box to bag” shift is very real and for good reason. If you are not already paying higher shipping costs due to dimensional weight, the bad news is that you soon will be. The good news however, is that you can still maintain or possibly even reduce your shipping costs by making a few changes to your e-commerce or subscription box packaging.

What is dimensional weight?

Essentially, package carriers are now charging for the space your package takes up in their system and truck. So the cost to ship a light product (example – apparel) in an oversized box is determined by the overall dimensions rather than just the weight as previously calculated for most packages. In other words, it used to not matter if the box or package was larger than it had to be, but now it does and you will be penalized with a new, higher rate.

Isn’t the best solution “right sizing” the box?

Right sizing any box is always a good idea and can result in substantial packaging and shipping cost reductions. However what happens when the size of the product being shipped varies month to month, or order to order? You will often end up shipping a box that is larger than it needs to be because it is very costly to create and stock a variety of branded box sizes to handle the changes in product dimensions.

Available custom printed with 25,000 minimumWhat are the advantages of mailer envelopes?

There are many varying factors but often times, they are lower in cost compared to some corrugated shipping containers. In addition to acquisition cost, they occupy less space on a truck or in your warehouse so the inbound shipping and storage costs are minimized.

In use, they also reduce packing labor because they do not have to be erected or taped. Most mailer envelopes have a convenient peel and seal strip that eliminates the need for additional tape to secure the contents.

The greatest advantage is the way they can conform to the product being shipped. There is no oversized penalty being paid because whether you are shipping one or three tee shirts (for example) the mailer envelope is always the perfect size.

What type of mailer envelope do you recommend?

It always depends on the application. What you ship, how you ship, and even how many you ship can influence our recommendation for you. Here are a few options we offer:

  1. Unpadded POLY mailer envelopes – very commonly used for apparel for their light weight and moisture resistance. 25,000 minimum for custom printing.
  2. Unpadded PAPER mailers – a very popular option for green minded customers with a very low one case minimum for custom printing.
  3. Padded POLY mailer envelopes – or as they are often called, bubble mailers, are a great option when a little package rigidity is desired and the product requires some cushioning or protection. Also has a 25,000 minimum for custom printing.
  4. Padded PAPER/POLY mailer envelopes – this is usually not one of our favorite options because when the inside bubble cushioning is laminated to the paper exterior, it renders the structure unrecyclable. However, they are lightweight and print up beautifully with a minimum 25,000.
  5. Paper board or RIGID mailers – these flat mailers are more versatile than most people think and they too can be process printed in a relatively low 25,000 minimum.

Shipping packages is growing increasingly complicated because there are so many costs to be considered. For many of our e-commerce and subscription box brand owners, packaging and shipping are two of the major costs they try to manage, so we have become well versed on how to help them accomplish that.

Please contact us at Salazar Packaging or call us at 630-551-1700 for a no cost, no obligation review of your specific application.

Related posts:

Read More

24 Apr 2015 E-Commerce Boxes that Sparkle and Shine

Litho label print on die cut mailerAt least once a week we receive an inquiry from someone attempting to create a unique brand and look on their e-commerce or subscription boxes by utilizing glossy or shiny graphics. This is can be accomplished a number of different ways but not through the standard or typical flexographic print process.

The limitations of flexographic printing on corrugated board

In most cases boxes are printed using water based (eco-friendly) inks that are printed directly on the corrugated substrate. This approach is economical and effective but results in a “flat” finish with no luster or gloss. The flat finish is most obvious when printing black or other dark flood coat colors and designs.

I often refer to this as an imperfect process being printed on an imperfect substrate because the printing is being done on an industrial grade paper (board) not fine, offset, or other high grade printing paper. That limits the print and finish options that are available.

standard on left, Kemi on rightA few sparkle and shine options

This is by no means a complete list and any number of combinations and variations are possible. Here are a few ways we can help you create the look you want- in increasing order, least glossy to most glossy:

Special or Display Inks – for a slightly higher level of gloss, it is possible at times to simply use a higher gloss ink. There are minimums and other restrictions but in some cases it is just enough to satisfy the need at minimal additional cost.

Kemi or Special Board – One of the ways to increase the amount of ink that stays on the surface of the board is to restrict or modify the porosity of the board. Rather than soaking into the board, the ink will often appear heavier and brighter.

Varnish and Aqueous Coatings – With equipment limitations and minimums applying we can apply or “print” an edge to edge “flood coat” or a limited “spot” coat of a variety of different gloss finishes. Different gloss levels can be combined for dramatic 3-D like images but keep in mind each adds cost and may require a separate print plate.

Litho Labels – Printing on fine (litho) paper, rather than direct printing on industrial grade board, a wide variety of print processes (offset, digital, etc.) and coatings are available. As an extreme example, it is possible to print a photo or brochure quality color image, coat it with a high gloss varnish and then laminate it to the corrugated board before creating a box out of it.

Laminates – A “poly” laminate can often be applied over a litho label or sometimes directly over the direct printed corrugated image to create a glass like surface to enhance and protect the design. There are a variety or laminate materials available and not all are considered eco-friendly so make sure you understand the impact of any specific finish to the recyclability or repulpability of the box after its use.

Price and minimums?

There are many factors that impact pricing including graphics and quantities being ordered. Generally this list of finish options is in least expensive to most expensive order and also reflects typical lowest to the highest minimums. So for example, litho labels or laminates will probably be cost prohibitive in quantities under 10,000 boxes but Kemi board or special inks, MAY be cost effective at 2,000 or 3,000 boxes.

There are no hard and fast rules other than your typical unprinted stock box source will probably NOT be able to help you. These are not your average or typical boxes so a level of experience is necessary to do it well, and at a reasonable cost.

Please do not hesitate to contact us at Salazar Packaging or call us at 630-551-1700 if you would like to discuss your specific application.

Related posts:


Read More

31 Mar 2015 Stock and Custom Printed Rigid Mailers Now Available

Available cusotm printed with 25,000 minimumGlobe Guard has offered and stocked unprinted poly and paper, padded and unpadded mailer envelopes for years and they are all available custom printed as well with varying MOQ’s. We have now added paper board “rigid” mailers for shipping products requiring additional protection, and they too are available branded and custom printed with your artwork.

Peel and seal strip is standardStock Rigid Mailer Sizes

These rigid mailers are standard with a peel and seal adhesive strip so they do not require taping, and the recipient will appreciate the easy open tear strip. The sizes that are in stock and available immediately are:

6” X 6” – 18 point mailers ideal for CD’s

6” X 8” – 24 point mailers perfect for gift cards

7” X 9” – 26 point mailers for small photos and greeting cards

9” X 11-1/2” – 26 point mailers ideal for 8-1/2” X 11” photos

9-3/4” X 12-1/4” – 26 point mailers ideal for certificates and documents

11” X 13-1/2” – 26 point mailers ideal for promotional materials

12-3/4” X 15” – 26 point mailers perfect for calendars

12-1/2” X 9-1/2” – lightweight, 14 point horizontal mailers for printed materials

All of these stock sizes are available on an introductory sale that runs through May 31, 2015. No promo code needed.

Easy Open tear strip is standardCustom Size and Custom Printed Rigid Mailers Also Available

We are able to provide you with beautiful custom printed mailers up to six colors with photo quality images. I would dare to say that your graphic artist cannot come up with a design that we cannot produce. The minimum for custom branded rigid mailers is 25,000.

Please contact us at Globe Guard Products or call us at 630-551-1700 if you have questions or need samples of our plain or custom printed rigid mailers. Also, keep in mind, the introductory rigid mailer sale on our green packaging store runs through the end of May, 2015.

Related posts:

Read More