Corrugated,
done properly.
Rolls, boxes, inserts, displays and print finishes — every one of them made from recyclable kraft board and engineered around the product it has to protect.
Stock & Bespoke
100% recyclable · FSC-certified kraft · Plastic-free
What we make
Carapace is a corrugated packaging manufacturer, not a reseller. Board is converted, printed, die-cut and glued under one roof, which is why we can hold a specification consistent across a hundred thousand units.
Every grade we run starts as FSC-certified or post-consumer recycled kraft. Nothing leaves the plant with plastic tape, plastic windows or plastic laminate unless a customer specifically asks for it — and we will usually talk you out of it.
In-house structural designers build custom-fitted boxes, internal inserts and display units engineered for strength first and shelf appeal second.
Standard, bespoke, or inner packaging
A stock RSC carton is the cheapest box you can buy — until you add void fill, pay to ship air, and absorb the damage claims that come with a loose fit.
Standard sizes save tooling cost and ship the same week. Bespoke die-cut boxes are engineered to the millimetre around your product, which removes filler, cuts dimensional freight weight and turns the opening into something a customer photographs.
We quote both, side by side, with the break-even volume marked — so the decision is a number, not a sales pitch.
Branding that survives the supply chain
Up to six-colour flexo for shipping cartons and four-colour offset litho lamination for retail-facing packs, finished with matt or gloss lamination, spot UV, embossing, debossing and foil.
All standard print runs use water-based and soy-based inks, so the finished pack still goes into the same kerbside recycling stream as a plain brown box.
Barcodes, batch codes, sequential numbering and QR codes can be printed variably, giving you traceability from the line to the customer's doorstep.
Recyclable by default, not by upgrade
Corrugated board is one of the most recovered packaging materials in the world — but only when it stays free of plastic film, foam and mixed-material laminates.
That is the constraint we design inside. Paper void fill instead of air pillows, honeycomb and moulded pulp instead of EPS, paper tape instead of PVC, and inserts cut from the same board as the carton so the whole pack goes into one bin.
If a brief genuinely needs a barrier coating or a cold-chain liner, we will say so and specify the most recoverable option available.
What actually moves the price of a box
Corrugated pricing is not a mystery — it comes down to how much fibre goes into the pack, how many times it passes through a machine, and how far it travels. Here is what we look at when we quote.
Get a Costed QuoteGSM & ply count
Higher GSM and more plies mean more fibre per box — and a higher unit cost.
Box dimensions
Larger boxes consume more board area, so price scales with the flat blank size.
Minimum order quantity
Higher volumes spread set-up and tooling across more units, lowering the per-unit cost.
Printing & coating
Extra colours, laminations and premium finishes each add a pass on the line.
Custom design
Die-cutting, inserts and bespoke structures carry one-time tooling and design cost.
Freight & delivery
Distance from the plant and load efficiency decide the final delivered cost.
Every quote includes the board grade, GSM, ply, print specification and delivered price — no hidden tooling or freight surprises.
Need custom sizes or high-volume pricing?
Speak directly with our structural packaging specialists for free CAD samples, custom flexo print designs, and instant quotes.
Request Custom Quote