Rigid Boxes Execution Step-by-step process - from a leading packaging company in Ahmedabad 

At Printwell, one of the most trusted rigid box manufacturers and a leading packaging company in Ahmedabad, we believe in delivering not just boxes, but an experience. In our last blog on Types of Rigid Boxes, we promised a detailed execution plan—and here it is.

This guide offers a complete breakdown of how rigid box packaging is conceptualised, developed, and delivered. Whether you're a startup or an established brand in pharma packaging, luxury gifting, or retail, this blog will help you navigate the rigid box manufacturing process.

1. Conceptualisation

Every project begins with a conversation. At this stage, we explore your product category, target audience, and competitors. As experienced rigid box manufacturers, we help you conceptualize a packaging solution that aligns with your product, brand story, and industry standards.

Key questions we address:

• Why do you need a rigid box?
• Will it serve as primary or secondary packaging?
• What quantity is required?
• Is it for retail display, gifting, or e-commerce shipping?

Example:
A 5-star hotel chain approached us for custom food-grade rigid boxes to pack cookies, donuts, and cupcakes. Since the food directly touched the box, we applied food-safe lamination and used low-odor adhesives. Packaging wasn't just visual—it had to be safe, regulatory compliant, and preserve freshness.

2. Kappa Board Selection

Material strength is a cornerstone of effective rigid box packaging. Based on our experience in pharma packaging printing and luxury goods, we recommend the ideal thickness:

• Standard: 1.5 mm – 2.0 mm
• Available range: 1.0 mm – 3.5 mm (custom bulk orders can go up to 4 mm)

Considerations:

• Product weight
• Whether the box is reusable or disposable
• Primary or shipping-grade use

3. Cavity Design & Material Selection

A rigid box isn’t complete without a properly designed cavity. This holds the product securely and elevates the unboxing experience.

Eco-friendly options we recommend:

• 350+ GSM laminated paper (ideal for pharma packaging)
• 1 mm – 1.3 mm kappa board
• EVA foam (for shock-absorption)

4. Outer Paper & Cover Material

“Packaging is the first tangible impression of your brand.”
The choice of wrapping material significantly influences perceived value.

Depending on your product:

• 170 GSM art paper with matt, gloss, or velvet lamination for printed boxes
• Fabric or PU leather covers for luxury jewellery or gifting
• Kraft paper for eco-conscious brands

Reflection points:

• What brand image do you want to create?
• What’s your cost-per-box threshold?

5. Printing Techniques

As a reputed pharma packaging printing company, we aim for precision, color consistency, and economic efficiency.

Recommended processes:

• UV drip-off or MetPet printing for luxury feel
• Pantone + CMYK for solid shades
• Gloss/Matt/Velvet Lamination for smooth finish

Most packaging companies in Ahmedabad often miss these details. At Printwell, we treat every square inch of the surface as branding space.

6. Enhancement Processes (Add-On Finishing)

These post-printing processes enhance product value and aesthetics.

We recommend:

• Spot UV: For sharp contrast and shine
• Texture UV: For tactile effect and elegance
• Foiling (Gold/Silver/Custom): For visual luxury
• Debossing/Embossing: For tactile branding
• Metallic Finishing: For reflective elegance

7. Key Line Drawing (KLD) Development

This is the design backbone of the box. Our pre-press team creates CDR, Illustrator, or InDesign files based on actual product measurements.

Thanks to our expertise in pharma packaging, our die lines are error-proof and development-ready.

8. Prototype Creation (Dummy Sample)

Before full-scale manufacturing, we create a sample box to test:

• Fit & finish
• Structural strength
• Design placement

While value-add processes (like Spot UV, Foiling, etc.) are not applied on prototypes, they are mapped out for final production.

Timeline:
Prototypes typically take 5–10 working days depending on complexity.

9. Feedback Loop & Continuous Improvement

“No packaging is perfect. There's always scope for refinement.”
After delivery or sample submission, we schedule feedback calls. Adjustments are made, and processes are optimized. This proactive approach ensures repeat business and better results every time.

Partnering with the Right Packaging Company in Ahmedabad

From a small commercial printer to becoming one of the most dependable packaging companies in Ahmedabad, our journey is built on trust, quality, and relationships—with clients, vendors, and our team.

We are proud to be among the few rigid box manufacturers in India offering end-to-end solutions, including for niche segments like pharma packaging and luxury gifting.

Let’s Create Something Remarkable Together

Are you looking for a packaging partner who understands your brand's needs as well as you do?
Printwell brings decades of experience in rigid box manufacturing, pharma packaging printing, and retail presentation.

📞 Contact us today at +91-9879444445 or email us info@printwellindia.com to transform your packaging into a brand asset.