Packaging Design — Retail Box, Blister, Bulk Carton

To brand owners, retailers and e-commerce sellers whose product arrives by somebody else’s van,

Tittron — the B2B division of FlykanTech — invites you to treat packaging as engineering rather than decoration. A retail box has to sell on a shelf, survive a pallet, stack in a warehouse and open without a knife; a mailer has to arrive without a corner dent that turns into a return. We design both, produce the dielines and the print files in-house, and test the result before the run starts.

Packaging is made in the same plant that builds the hardware, which means dielines are drawn against the real product, prototypes are packed with real units, and a design change does not wait on an outside printer. It also means packaging can be produced in the same run as a small batch instead of a container-load commitment.

Tell us the channel, the transport and the shelf. We will return format options, structural drawings, artwork proofs and a tested prototype — before anything is printed in quantity.

The Tittron teamB2B division of FlykanTech · www.tittron.com

What the service actually solves

Packaging does two jobs that pull in different directions: it has to present the product and protect it. Retail packaging leans towards presentation — window, hanging tab, brand face, shelf footprint. E-commerce packaging leans towards protection — drop resistance, void fill, closure strength, and a size that does not trigger a surcharge.

We design for the channel the product actually goes through, and we test against the transport it actually faces. A drop test from the height a parcel network uses, a stack test for the pallet height your warehouse uses, a vibration run for the route your freight takes: these are cheap before production and expensive after it.

The structural design and the artwork come out of the same place as the product, so the dieline matches the unit, the insert fits the accessory set, and the printed carton matches the declared contents. That is what keeps a shipment from being repacked at the destination.

From channel brief to tested prototype

01
Channel and transport brief

Tell us where the product is sold, how it ships and what the packaging has to do on arrival — hang on a peg, stand on a shelf, survive a parcel network, or stack on a pallet.
- Retail, e-commerce, bulk distribution or a mix
- Transport mode and parcel network standards noted for testing
- Shelf footprint, hanging and stacking requirements captured
02
Format options

We propose the formats that suit that channel — retail box, blister, bulk carton, mailer — with the cost, minimum and protection level of each laid side by side.
- Cost per unit quoted per format, including printing method
- Minimum print quantity stated per format
- Protection level described honestly: what each format survives and what it does not
03
Structural design and dieline

The structure is drawn against the real product and its accessories, with board grade, insert design and closure specified, and a dieline produced for approval.
- Dieline drawn from the actual unit dimensions, not from a generic template
- Insert designed around the accessory set so nothing rattles
- Board grade and closure chosen for the transport mode named in the brief
04
Artwork and proof

Print artwork is laid out to your brand on the approved dieline, including regulatory text, barcode, carton marks and language versions for each market.
- Artwork on dieline, with print-ready files produced in-house
- Barcode, EAN and carton marks included
- Language versions produced per market from the same layout
05
Prototype and testing

A prototype is packed with real units and tested — drop, stack and vibration — before the print run is committed. Findings go into the structure, not into a note.
- Drop test from the height your parcel network specifies
- Stack test for the pallet height your warehouse uses
- Prototypes packed with real product and real accessories
06
Production and packing

Approved cartons are printed and used in the same run as the hardware, with packing checked during inspection rather than discovered at goods-in.
- Printed in the same plant as assembly
- Packing quality included in the AQL inspection
- Reorders use the stored dieline and artwork at the same minimum

The numbers, at a glance

Formats	Retail box, blister, bulk carton, e-commerce mailer
Minimum print quantity	500 pieces for a printed retail box; 1,000 for blister tooling
Structural design	3–5 working days from the product and channel brief
Prototype	5–10 working days, packed with real units
Testing	Drop, stack and vibration against the transport mode you named
Print methods	Offset for retail cartons, digital for short runs, flexo for bulk cartons
Languages	Per-market artwork versions from one layout
Reorders	Stored dieline and artwork; same minimum, no new tooling

The figures below are typical values. The quotation states the exact minimums, lead time and commercial terms for your specific programme.

What we actually do

Structural design

Cartons, blisters, inserts and mailers designed around the actual product and its accessories, with board grade and closure specified for the transport mode rather than for the drawing.

Artwork and print

Print artwork laid out to your brand on the approved dieline, with offset, digital and flexo options chosen by run length, and files produced in-house.

Transport testing

Drop, stack and vibration testing against parcel-network and pallet standards, run on prototypes packed with real product before the print run is committed.

Market-ready versions

Per-market artwork with the right language, regulatory text, barcode and carton marks, produced from one layout so every destination version stays consistent.

Three ways programmes usually start

Retail box

Printed carton with brand face, window or hanging tab, designed for shelf presentation and tested for the pallet it ships on. The standard choice for branded ranges.

Bulk and e-commerce

Plain or printed carton engineered for protection and dimensional weight, with inserts sized to the accessory set. The choice for parcel networks and FBA shipments.

Blister and hanging pack

Retail blister or hanging pack for peg presentation, with tooling quoted up front. Highest minimum, strongest shelf presence.

Who this invitation is for

Retailers and retail-ready brands

Products that have to sell from a shelf or a peg, with a brand face, a barcode and a footprint the planogram allows.

E-commerce and marketplace sellers

Sellers whose returns are driven by transit damage and dimensional weight, where a mailer designed for the network costs less than the parcels it saves.

Distributors and wholesalers

Bulk cartons that stack, palletise and identify their contents without being opened, with carton marks that match the packing list.

Private label programmes

Brands whose packaging is the first thing a customer sees and has to match the housing branding, the manual and the warranty card.

The resources behind it

These sit inside the same organisation — that is why the work can be quoted, built and shipped as one programme.

Designed where the product is built

Dielines drawn against the real unit and prototypes packed with real product, because the packaging team works in the same plant as assembly.

Printing in-house

Offset, digital and flexo printing available at the same site, which is why short runs are possible and a design change does not wait on an outside printer.

Test capability

Drop, stack and vibration testing run before the print run, so a structural weakness is found in a prototype rather than in a customer return.

Documentation alignment

Packaging artwork, manual, warranty card and carton marks produced from one brand set, so the declared contents match what the box actually contains.

Commercial terms

Structural design	Included for programmes we produce; quoted separately for design-only work
Minimum print quantity	500 for printed cartons; 1,000 where blister tooling is required
Tooling	Blister tooling quoted up front and owned by you
Prototypes	Two prototype rounds included; further rounds quoted at cost
Testing	Drop, stack and vibration included for e-commerce programmes; additional standards quoted
Reorders	Stored dieline and artwork; same minimum, no repeat tooling cost
Confidentiality	NDA on request — your artwork and dielines stay with us
Inspection	Packing quality included in the AQL inspection, with photos per shipment

Standard terms for a first programme. Framework agreements, payment terms and exclusivity are open to discussion from the second order onwards.

What buyers ask first

What is the minimum for custom printed packaging?

500 pieces for a printed retail carton using digital or offset print, and around 1,000 where blister tooling is needed. Below 500, a printed label or sleeve on a standard carton usually gets the same shelf result, and we will say so if that is the cheaper route.

Do you test the packaging before printing?

Yes for e-commerce and any programme where transport is the risk. A prototype is packed with real units and accessories and put through drop, stack and vibration testing against the network or pallet standard you named. Findings change the structure before the print run, not after it.

Can you produce different language versions of the same box?

Yes. Market versions are produced from one layout with the language, regulatory text and barcode changed per destination. That keeps the brand face identical across markets while the back panel satisfies each one.

Will the packaging fit FBA or marketplace requirements?

It can be designed to. Tell us the channel at the brief stage and we design to its requirements — labelling, carton marks, dimensional weight and closure strength — rather than adapting a retail box afterwards and hoping it passes.

Who owns the dieline and the artwork?

You do. Dielines, artwork and print files are stored against your programme reference and reused for reorders at the same minimum with no repeat tooling or design charge.

Packaging design — engineered for the shelf and for the journey