5 Unexpected Benefits of Switching to Custom Paperboard Packaging

You have probably heard all the usual reasons to switch to custom paperboard packaging. It's eco-friendly, it's affordable, and customers like it.

But after working with dozens of brands that made the switch, we have noticed some benefits that nobody really talks about. The kind that actually moves the needle for your business in ways you didn't see coming.

Let me walk you through five benefits that caught even seasoned brand owners by surprise.

5 Surprising Benefits of Using Custom Paperboard Packaging

1. Your Warehouse Team Will Actually Thank You

Here's something that doesn't show up in packaging brochures: paperboard is ridiculously easy to work with. We are talking about the day-to-day reality of running a business.

Think about plastic clamshells or rigid boxes for a second. They take up space even when they're empty. They're awkward to stack. Your team needs box cutters, and someone always ends up with a slice on their finger.

Paperboard packaging arrives flat. A box that holds 100 plastic containers might hold 1,000 flat paperboard pieces in the same space. When your storage room is already bursting, that difference matters. Your warehouse manager will notice it immediately.

2. You Can Test Ideas

Paperboard packaging lets you test multiple ideas simultaneously. And most packaging requires huge minimum orders.

Paperboard is different. The setup costs are lower, and plenty of manufacturers work with smaller runs. Some will do 500 units. A few will go even lower if you are willing to pay a bit more per piece.

This changes how you can run your business. Suddenly, you can test a holiday design without ordering enough for three seasons. You can create a limited edition for one event. You can run two different designs and see which one your customers actually prefer instead of just guessing.

3. Shipping Costs Drop (And Nobody Sees It Coming)

Everyone knows paperboard is lighter than other packaging materials. What they don't realize is how much that weight difference hits your shipping bill.

Dimensional weight pricing means carriers charge you based on size and weight, whichever is higher. A bulky plastic package might push you into the next pricing tier even if the product inside weighs nothing. Paperboard keeps your profile slim.

But here's the part that really surprised me: the damage rates. Paperboard has some give to it. It absorbs shock. Rigid plastic containers crack. Glass breaks. Metal dents. Paperboard flexes, and your product stays safe inside.

4. Customers Keep the Packaging (Free Marketing)

The packaging that is hard to recycle is thrown away by customers. But paperboard packaging can be easily recycled, and customers keep this type of packaging.

Nice paperboard packaging? People keep it. They use it to organize drawers. They store jewelry in it. They save it for regifting. We have seen custom-printed boxes sitting on bathroom counters six months after purchase because they look good and they're useful.

Every time someone sees that box sitting on their friend's shelf, that's a brand impression you didn't pay for. Every time they pull it out of a drawer, they see your logo again. The packaging keeps working long after the purchase.

5. Print Quality That Makes Designers Weep

Print quality works best on paperboard material. The matte finish looks amazing, and deep colors pop without making it cheap. Glossy coatings add depth. Spot UV creates contrast that photographs beautifully.

Your designer can finally use those subtle gradients they have been dreaming about. Paperboard handles it. Those tiny details in your logo? They will actually show up. That custom illustration you commissioned? It'll look exactly how it does on screen.

Compare that to printing on plastic, where colors can look washed out or inconsistent. Or printing directly on metal, which limits your options severely. Paperboard gives designers an actual canvas to work with.

The Bottom Line!

Custom paperboard packaging is more than just about jumping on the sustainability trend or saving a few cents per unit. The real benefits show up in operational efficiency, market flexibility, shipping logistics, long-term brand presence, and premium positioning.

The brands that figure this out early get ahead. The ones that dismiss it as just another packaging option miss the advantages hiding in plain sight. Sometimes the smallest changes create the biggest ripples.

Contact Kolaxo Print to get ready paperboard packaging for your brand.