Rigid packaging refers to sturdy and nonflexible packaging materials. Made from high-quality paperboard, this material is renowned for its strength and resistance to damage after being shaped into a premium box. Unlike flexible packaging, which cannot maintain shape and structure, rigid packaging offers additional benefits with secured transportation.
Its manufacturing process has some important steps, which include fine-quality paperboard gathering and greyboard raw materials and then pulping them to form sheets that are glued together and transformed into boxes. In personalization, Custom rigid box packaging enhances beauty by adding embellishments like printing, foiling, lamination, embossing & debossing, and inserts. Considering its growth statistics, this material is expected to gain a significant market share in the coming years. From cosmetics to electronics, the applications of sturdy packaging are vast, making it a versatile choice for various industries.
Rigid Packaging Market Size and Growth Rate
According to a growth market report, the global sturdy box packaging market is valued at approximately $ 412.7 billion in 2022 and is expected to reach almost $665.52 billion by 2031. The average growth rate of the market is estimated at 61.2% based on the fact that sturdy packaging has a rise in demand in the global market. This massive growth is mainly due to increased demand for sturdy packaging solutions. Whether a startup or a well-established business, everyone is looking for the best packaging solutions they can see in sturdy boxes and tends to be more inclined toward them.
What Makes Rigid Stand Out from the Rest of the Packaging?
Basically, these boxes offer structural support to the product, unlike the kraft or card material options available that cannot bear the minimum weight and easily collapse during transportation. Maintaining integrity makes them more beneficial, especially for items that require extra protection or those with irregular shapes that may not fit well in flexible packaging. Moreover, the secure open and closure mechanisms these kinds of boxes offer further add to the safety seal for the products inside, which ultimately drives success in the market.
Its customization options include every possibility, from eco-friendliness to something that is not more sustainable but provides equal benefits. It totally depends on the material selection and what you want to achieve with the package. Top brands like Dior’s Nike Jordan 1 High sneakers or Gucci’s Tennis 1977 sneakers exemplify the level of packaging perfection and get features among various top fashion brands.
Types of Material Used in Rigid Packaging
The primary materials considered rigid are typically paperboard and cardboard. Each material offers unique properties and characteristics that make it suitable for different packaging needs:
- Paperboard: Due to its versatility and strength, paperboard is a thick, durable paper stock often used for rigid packaging. It comes in various grades and thicknesses, allowing customization according to specific requirements. Paperboard is commonly used for luxury packaging, such as high-end cosmetics, electronics, and food items.
- Cardboard: Cardboard is a thick, stiff, paper-based material consisting of two or more layers of paperboard. Due to its durability and affordability, it is widely used for rigid packaging. Cardboard boxes are commonly used for shipping, storage, and retail packaging across various industries.
However, customizations also vary, including different layers of kraft paper and coatings or laminations on the surface, which can be tailored to a specific purpose.
How is it made?
From selecting raw materials to printing and having the final product, the entire process is a blend of expert solutions and innovative techniques that are required to give your product the best packaging ever. Its manufacturing processes include:
Rigid Boxes Manufacturing Process
Can you classify the manufacturing process of this packaging?
It seems like rocket science but seriously, it’s not!
The technicalities of making packaging strong and durable are important to consider, especially when they are for retail or commercial purposes, and include three main stages.
- Concept visualization
From the beginning, you should clearly understand what your box will look like and how your product will be showcased. From the box’s exterior to the interior inserts, every detail should be transparent and narrated to the specialists who will build it for you. At this stage, you have to consider the following points:
- The quantity required
- The customizations you will add will make it more attractive.
- How conveniently will it carry your product, and what measures will be added to enhance its attractiveness while maintaining its practicality and integrity?
Moreover, the customization options are not limited to those outside the box. It differs from where it is going to be used. For instance, in the food industry, the interior of a box has either partitions of paperboard, foam sheet, or polypropylene plastic to ensure the safety of the food inside.
Hearing plastic in sustainable packaging might sound off-putting, but that’s not the case with polypropylene plastic films, which are considered to be the most human-safe material. These films are heat-friendly and can be used to cover food products like chocolates, biscuits, etc.
- Production
To achieve the precise and desired results, the production has to be accurate, either manually or mechanically. Everything should be taken care of with attention, from the use of high-quality chipboards to their mixing with other materials in the production process. To achieve a premium quality box, it undergoes the following process:
- Material Preparation:
Cardboard Stamping: Sheets of cardboard are stamped with other raw materials like chipboard or greyboards to create the structural elements of the boxes. This involves cutting and shaping the cardboard into the desired box shapes.
- Assembly:
Inner Carton Folding: Separate pieces of cardboard are folded and assembled to form the inner cartons of the gift boxes. This step ensures that the contents of the box are securely held in place. This also includes variations of inserts like extra cushioning, etc., according to the customizations provided.
Stapling for Reinforcement: Once the inner cartons are formed, they are glued or stapled together to reinforce their structure, making them sturdy and durable.
- Final Assembly:
Bonding with Adhesives: Mainly, latex adhesive is applied to various parts of the box components to securely bond them together. This ensures that the boxes maintain their shape and integrity during handling and transportation.
- Lamination or Coating:
Protective Coating Application: After the boxes are assembled and bonded, a protective coating, such as lamination, is applied to the outer surface of the boxes. This coating helps preserve the printing and enhances the durability of the boxes, making them more resistant to wear and tear.
- Shipment
Your product must be cleaned and protected, and the packaging must be handled and transported with the utmost care. After getting the final product ready, the sturdy boxes are sealed in a tamper-proof corrugated box with proper cushioning material to avoid any damage during transportation.
What makes Rigid Packaging Hard?
These rigid, sturdy boxes get their strength and durability from the quality materials that are glued together to form a box. The more layers of cardboard along with other materials, including chipboard, greyboard or even fillings with plastic, the harder it will be. The more layered it is, the more it will form a stiff and tough structure that will serve as the perfect box for your luxury, high end products.
Differences Between Rigid & Flexible Packaging Material
Rigid boxes are different and more demanding than flexible packaging. Rigid packaging provides robust protection and guarantees the secure transmission of goods from one place to another, while flexible packaging is flimsy and risky for luxury products. Some critical differences between rigid and flexible packaging include:
| Flexible | Rigid |
| Thin, bendable materials like not so thick paperboard, plastic films, pouches, etc. | Sturdy materials like cardboard, plastic, and metal. |
| Lacks structure when empty | Holds shape, even when empty |
| Limited protection against external factors | Provides maximum protection |
| Less rigid and affects shelf life of the products | Projects premium appearance while maintaining product’s integrity |
| Recyclability and reusability are low due to the mix of other materials | Typically easier to recycle |
Pros & Cons of Using this Rigid Premium Packaging
The practical approach to rigid covers is that they offer a range of benefits, such as:
Advantages of Rigid Packaging
- Sturdy and Durable: Sturdy packaging, especially boxes made from cardboard material, provides excellent protection for products during storage and transportation.
- Premium Presentation: Strong and sturdy boxes offer a high-quality, upscale appearance that can enhance the perceived value of the packaged products.
- Customization Options: These boxes can be easily customized with printing, embossing, or other finishing techniques to showcase branding and product information.
Disadvantages of Rigid Packaging
- Cost: Rigid packaging, particularly custom-designed boxes, can be more expensive to produce compared to flexible packaging options.
- Storage Space: Setup boxes take up more space, which can be a consideration for businesses with limited storage capacity.
How can Rigid Materials Extend the Shelf Life of Your Products?
Rigid plays a vital role in extending the shelf life of products by providing a protective barrier against external factors like moisture, light, and air. The sturdy construction of boxes helps prevent crushing or damage to the packaged items, preserving their integrity and freshness over time.
Additionally, rigid packaging can be designed with features like inner liners or seals to create an airtight environment, further enhancing product shelf life by minimizing exposure to oxygen and moisture.
Benefits of Rigid Packaging
- Brand Visibility: The firm and resilient setup boxes can be one of your best options for ensuring that your brand’s message is clearly seen by your target market. This also increases the visibility and recognition of your brand.
- Eco-Friendly Options: Many rigid packaging materials, including cardboard, are recyclable and biodegradable, making them environmentally friendly choices for businesses and consumers.
- Reusability: This solid packaging can often be reused for storage or other purposes, which means that after unboxing your product, you don’t have to worry about discarding the box and using it for something else.
- Product Protection: Rigid packaging provides superior protection for fragile or delicate items, safeguarding them from damage during handling and shipping.
- Enhanced Consumer Experience: The premium look and feel of rigid packaging can contribute to a positive consumer experience, which ultimately provokes repeat purchases.
Industries that use Rigid Packaging
In the past few years, more industries have been turning to investing more in their packaging. This is because the demand for rigid packaging has increased significantly.
According to a report from The Smithers, there are growth opportunities for plastic rigid packaging by making it sustainable with advanced technology. The utilization of these setup boxes can be widely seen in food, beverage, cosmetic, pharmaceutical, and gift packaging, where the product demands premium cases, making rigid material an ideal choice.
When it comes to making your packaging more sturdy while maintaining sustainability measurements, the options might seem endless. However, only some products are suitable for a rigid packaging solution. Some industries opt for semi-rigid packaging, which combines the benefits of flexible packaging. The best example of this is aluminum. Furthermore, both packaging types are utilized accordingly for their different purposes.
- Electronics Industry: Protecting delicate devices like smartphones and tablets from damage during shipping and storage is essential. So, to ensure that manufacturers opt for strong and durable boxes that keep their products safe from bumps and knocks during transportation.
- Food and Beverage Sector: Rigid and semi-rigid materials can be used here, depending on the product type. Maintaining the freshness and quality of food items such as chocolates, confectionery, and gourmet treats ensures they arrive in perfect condition and look appealing on store shelves.
- Healthcare Field: Setup boxes are crucial for safely storing and transporting medical devices, pharmaceuticals, and diagnostic kits, ensuring they remain intact and meet regulatory requirements. In this case, semi-rigid boxes may not be the best option.
Why do Industries prefer Rigid Packaging?
As brands get hyped among their customers, they are upgrading their standards in every aspect. Making packaging premium and attractive is one of the most crucial strategies that anyone could ever take. If the packaging is top-notch, the product will have a better chance of grabbing consumers’ attention. Across many industries, sturdy packaging wins the battle to keep the products safe and secure while maintaining aesthetic appeal.
- Retail Brands
Major retail brands incorporate sturdy packaging for their precious customers. Moreover, they want to please their customers and uphold their brand value by providing boxes with unique coatings, resulting in a positive unboxing experience.
Various top fashion brands, like Revlon or Loreal, target women who understand that they need to make an impact with their product packaging. As a result, they utilize innovative packaging boxes like Unilever, which uses elegant, rigid style packaging to sell their LUX hand wash products to their delicate audience.
- Ecommerce Stores
Many E-Commerce stores have realized the importance of sturdy packaging. Whether they are startups or well-established companies, they want to build a reliable brand image. Flexible packaging or any other type of packaging can be risky, as the products can get damaged due to mishandling or rough transportation. This is why sturdy packaging is a must for E-Commerce stores.
- Brand Promotions
From elite brands like Apple, Nike, and Adidas to local brands, every company wants to build a strong brand identity, which they achieve through their high-end boxes. Just a logo and some additional inserts can transform a plain box into something that leaves a lasting impression on the customer.
- Industrial Sector
There is also quite a demand for high-quality box packaging among many premium brand industries that seek to strengthen their bond with loyal customers. As a result, they wish to deliver tailored packaging solutions for their products, which increase positive brand image and maintain a competitive edge.
For example, if you order a MacBook, you expect something other than the best, so it would be illogical to expect an inferior printing or packaging box. As soon as you unbox your Apple product, you will feel that the box is sturdy and has precise printing. You will find separate partitions for your adapter, cable, and other accessories inside it. This is the beauty of premium packaging and the level of presentation sophistication.
- Luxury Products
You want to experience luxury products in the most premium, sturdy, and rigid packaging boxes. People expect nothing but the best when they buy luxury goods like expensive mobile phones or jewelry products, so they expect premium material packaging. Luxury product design ideas
According to a survey report published by the Statista Research Department in 2023, the global luxury packaging market is expected to reach above $22 billion by 2025.
Top-tier perfume manufacturers like Gucci, Versace, and Hugo Boss present their premium products nicely packaged in beautiful boxes.
Design Ideas to make a Rigid Package, Customized
When it comes to pack high-end items that need an extra touch of perfection, set-up boxes are the best solution. However, its box design ideas vary with the product type and its purpose. From the premium look to their ultimate protection, every box is designed to the best of their quality. Not only rigid cardboard boxes are utilized in luxury packaging, but plastic, metal, and wood materials are also used in rare cases.
Besides paperboard, the material choices can get complex because of the higher MOQs (minimum order quantity) and the mold formations with other steps included. Customization possibilities are endless, and various options are available in the style catalog of sturdy packaging. From box designs to custom add-ons and inserts, you can get the product you have visualized and are looking for. For example,
- Two Piece Style: These are the classic “shoebox style” set-up hard boxes and are the most commonly used. Moreover, they comprise a bottom and lid base that provide a unique unboxing experience for premium brand products.
- Sleeve Style: These sleeve-style presentation boxes have a similar shape to the packaging of matchboxes. The outer box packaging can be opened using a ribbon or through the insert opening provided. Moreover, some of the brands also use rigid drawer boxes because they attract customers for first-time purchases due to their unique packaging shapes at major retail shop displays like Tesco or Walmart.
- Gable Rigid Box: These are the most unique and creative box styles to showcase your products. Like the happy meals but more sturdy, classy and with an easy mechanism of opening and closing.
- Hinged Style: This form of box packaging uses a hinge system to open and close the box. Moreover, this provides a smooth unboxing experience and is perfect for luxury products like watches or jewelry.
- Bookend Style: This form of box packaging functions like a book and provides ideal protection for small products placed inside. The outer layer is a hardcover and ideal for branded products like jewelry, mobile phones, or accessories. Companies that wish to please their customers elegantly often choose bookend boxes for their precious and valued products.
- Round Style: This innovative style of sturdy packaging provides an excellent way to present branded products like watches or jewelry to customers, creating an exciting experience of prestige and elegance that represents high brand values.
- Closure Style: This unique style of packaging incorporates magnets for opening and closing the packaging box. When closed, the box creates a pleasing snapping sound, with a luxurious cover providing ideal product protection.
- Collapsible Style: This type of box provides flexibility as it is foldable and can be easily assembled. These collapsible boxes are also ideal for retailers as they transport quickly and easily, providing space-saving opportunities.
Add-Ons and Custom Inserts
Regarding the endless possibilities of customization, robust boxes also welcome a variety of printing techniques and other add ons that can be used to enhance the look and appeal of the packaging, such as:
- Spot Gloss: This unique coating proves the best glossy finishing as it hardens quickly due to UV light exposure. Moreover, they can also be embossed, but foil stamping does not apply to them. Using spot gloss, your package lettering will become more prominent while reinforcing your premium brand image.
- Embossing and Debossing: The process of adding a raised or recessed texture to the surface of the packaging box is also another option that fits perfectly with these resilient packaging options.
- Hot Foil Stamping: Many brands and companies utilize this unique finishing for packaging their products by using pressure and heat to apply various designs and patterns of colors like silver, gold, red, and white. Moreover, metallic hot foil patterns and finishing can also be utilized through durable packaging containers for premium products.
- Specialized Coating: Most of the brands have finally understood the psyche of their targeted audience and how they respond to their products and services. The more added flair, the better the packaging looks. Therefore, printing companies have recently begun to focus on coating their sturdy packaging with:
- Aqueous Coating: A unique water-based coating that provides packaging boxes, a matte or glossy appearance. This coating also provides food safety and is extensively used in the food rigid packaging industry.
- Varnish: This unique coating is made from a thin, glossy, or matte layer on custom box wrap. It is utilized to highlight specific areas or entire wrap sheets for the best packaging presentation.
- Lamination: The lamination process uses very thin polypropylene plastic film to wrap premium products in a packaging box. Furthermore, the method provides more protection than standard box finishing options like varnish. This makes it ideal for scratch resistance and safety for branded products.
In Short; What is rigid Packaging
The rise of sturdy packaging is transforming how products are presented and protected. From cosmetics to electronics, brands are turning to rigid packaging for its durability and customizable options. This trend reflects a growing demand for premium packaging solutions that not only safeguard products but also enhance their perceived value.
Looking ahead, the sturdy packaging market is ready for continued growth, driven by consumer expectations and industry innovation. As brands explore new ways to stand out on shelves and online, these setup packaging will play an increasingly important role in shaping consumer perceptions and driving brand success.
