We often give the advice to startup businesses and new entrepreneurs that “they will know a lot more in 6 months.” That is to say, we don’t typically recommend launching a product line with all of the packaging bells and whistles if not absolutely necessary. Starting a bit more minimalistic or basic can be a huge cost-saving choice when factoring in initial tooling/print plate and other costs associated with custom packaging.
Along with this advice and road map comes the reassurance that you can always upgrade your packaging later, once you have a better handle on what is selling and what feedback your customers are providing. These upgrades can come in many forms, and we often refer to them as packaging redesign options. What follows are a few of the more popular redesign choices and the potential processes and costs involved.
Change Board or Ink Colors
This is a great option because it is typically very minimal to no cost added to an existing box, insert or envelope. If you are already buying printed boxes and you want to change the ink color from red to blue, there is usually no added cost to do this. You can even split a production run to print half of the order in one color and the other half in another for a small ink change fee. Changing board color may result in a slightly higher cost (4-8% roughly) if going from kraft brown to white board, but this is one of the lower cost redesign options. A fresh look can make a world of difference to your brand and provide the appearance of completely new packaging at virtually no cost.
Graphic Redesign/New Printing Method
This can encompass a wide variety. A graphic redesign may simply mean tweaking a few words or a logo, adding inside print to an existing exterior print box. Or it could be a complete graphic redesign which requires a printing method change, such as switching from a flexographic print to a digital print. You can see in the mailer envelope example below, the image left was a 1 color flexographic print, and the image right was a multi-color digital print. After many years with the same graphic design, the customer wanted their packaging to best reflect their logo as seen on social media/websites etc. Sometimes the reverse is also true, where a company will elect to scale back a complex design from an initial launch to something more basic for future reorders and subscription models. The graphics will ultimately determine the best printing method, and we have the knowledge and experience to best guide you and your graphic artists to understand your options and how to save costs when needed. It’s all about what you are trying to accomplish, and we can find the right balance of great custom branding at the lowest possible cost because we have seen it all! If you want to know more about graphic redesign, please visit our packaging graphic design page.
Structural Redesign/New Packaging Product
At Salazar Packaging, we are an industry leader in structural packaging design. As your company grows and matures, you will better know your products and your customers and be able to best tailor your custom packaging to your needs by redesigning, resizing, refitting or adding/eliminating components such as interior protective packaging. We can help design an insert for an existing mailer box, or create a new box, right-sized to your product to help reduce excess shipping and/or storage costs. We can create reusable/resealable mailers. We can help you create both a beautiful and fashionable influencer box, and a functional subscription box. Everything we do is in service to your needs, whether it be cost savings, reducing packaging skus, creating the best protective packaging, or the most memorable unboxing experience.
If you want to know more about structural redesign, please visit our packaging design services page.
Looking for a packaging redesign in 2025? Look no further than Salazar Packaging. We are ready and waiting to hear from you and help you achieve the look you want for the lowest possible cost.
Please Contact Us Today
As always, if you have any questions, one of our branded packaging advisors is standing by to assist, with decades of experience behind them. Want to know more about custom packaging options? Please call us at 630-551-1700 or contact us via email at www.SalazarPackaging.com.
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https://www.salazarpackaging.com/custom-packaging-for-apparel-and-clothing/
https://www.salazarpackaging.com/the-unboxing-experience-still-matters-in-2025/
https://www.salazarpackaging.com/how-to-improve-your-customers-unboxing-experience/
