Hi Jennifer, we just went thru this very thing! Here`s our problem and solution
We are new to the industry and don`t know if we will ultimately get aisle space when we get into larger stores, some stores want small displays on the counter, while some tell us that in the future they want floor displays. When you are also dealing with issues of quantity the product needs to fit well. So, we consulted the packaging company that we ordered our shipping boxes from. They wanted a ton of money before a floor display was even cut or printed. It was way out of our budget AND we didn`t know if this would be our long term display anyway.
We looked in the phone book for `DIE CUTTER` and found a small outfit down the road from us. With the $95 set up fee, cost of building the die, our cost for materials (enough for 200 boxes), and 200 punches = approx $500
We went out and found the paperboard material at a company called Expedx
and purchased our materials. (keep in mind that your die cutter could probably get their hands on the material for less expensive but we wanted to have things move faster - so we paid retail)
John designed a box for us by cutting out the paper board. He then made a rendering for the die cutter so she could price it, with exact measurements on the rendering. If you go this route, you have to be VERY specific as to where you need scoring (for folds) as well as your obvious cuts so the quote can be accurate. It is best to give them a sample box that you design with your product inside and how you want it to be inside the box. That way, if they are off on their first cut they will know that the die needs to be modified. Can`t imagine anything worse than getting all boxes and the product doesn`t fit.
We found a very inexpensive print shop who will be making us 4 ft x 8 ft sheets of our graphics in sticker form that we will then slap on the boxes. I think that cost is approx $80 which will give us enough stickers for a ton of boxes.
This works well for us to keep our initial costs down while we figure out what will work for the long term.
Another solution that would work for just a few boxes.....visit www.uline.com
as they have lots of different options for boxes. The nice part is that you can buy only a few at a time. Then you could get graphics printed in sticker form as in the example above. The only reason we didn`t go this route is because our product wouldn`t fit `just right` in their standard options. You will pay way more on price per box than the above scenario but if you only need a couple it might be the best solution.
A good way to figure out how to design a box is to go to one of your local stores, even a drug store, and ask the manager if you can take one of their nearly empty POS boxes that is otherwise going to be trashed. Most all the time they are going to be thrown in the trash. I even got some from my local Wal-Mart just for asking. That way you can dismantle the box to understand how the folds and cuts all work together.
Send me a PM if you need assistance with building a prototype box. My husband might be able to help you out.
I hope this helps!!!
Tammy Richardson, President
Tape-Seal by Greystone Design, Inc.
Tape-Seal Stops Paint Bleed
602-434-7182 Tammy`s mobile