Custom Setup Boxes

They are the same construction — "setup box" is the traditional term for a pre-assembled rigid box.

A setup box is a pre-assembled rigid box — the two terms refer to the same construction. "Rigid box" is the modern term used across the packaging industry; "setup box" is the traditional term used in North America and in the confectionery and stationery trades. Both describe a box built from 1.5–2.5mm greyboard, wrapped in art or specialty paper, and shipped pre-assembled. If you are evaluating suppliers, ask whether they wrap-and-assemble in-house or outsource — in-house wrapping is the quality benchmark.

Setup boxes are non-collapsible (ship pre-assembled); magnetic boxes are collapsible rigid (ship flat).

A setup box is a non-collapsible rigid box — it ships in its assembled form and cannot fold flat. A magnetic box is a collapsible rigid box — it ships flat and snaps together in seconds at the packing station, with a magnetic front-flap closure. Setup boxes have a stronger premium signal (no fold lines, no assembly) but cost more in freight volume. Magnetic boxes are the cost-effective alternative when freight volume matters. Choose setup for retail counter and gift programs; choose magnetic for DTC ecommerce.

Pre-assembled — setup boxes do not ship flat.

Setup boxes ship pre-assembled by definition — the format is defined by being non-collapsible. Pre-assembled shipping means higher freight volume (and higher per-unit freight cost) than flat-shippable formats like magnetic or folding carton. Plan freight volume accordingly — a pre-assembled setup box takes roughly 2.5× the freight volume of a flat-packed magnetic box of the same size. For most clients, sea freight keeps the per-unit freight cost manageable.

Yes — 7–10 business days for a printed sample, 5–7 for a white sample.

We provide white samples (unprinted, exact construction) in 5–7 business days and printed samples (your artwork, finish, and color) in 7–10 business days. Sample fees are credited back against your production order. We recommend a printed sample for any project involving Pantone matching, foil, or specialty paper, because colors and finishes render differently on physical stock than on screen.

Yes — either a separate lift-off lid (two-piece setup) or an attached hinged lid.

Two options: a separate lift-off lid (the two-piece setup variant, where the lid lifts off vertically — the most traditional setup format) or an attached lid that opens on a spine hinge (the book-style setup variant). The lift-off lid is the default for confectionery and gift sets; the hinged lid is the default for counter goods and heritage products. Both are quoted at the same cost unless the hinged lid requires spine scoring.

Yes — greyboard and paper wraps are recyclable in standard paper streams.

Greyboard and paperboard are both recyclable in standard paper streams. If you choose a wrap with foil stamping or soft-touch lamination, recyclability is reduced — check with your local recycler. For brands making a sustainability claim on-pack, choose FSC-certified wrap, water-based lamination, and skip foil. We supply chain-of-custody documentation for all FSC-certified projects.

10–15 business days after sample approval.

Standard production runs 10–15 business days after sample approval. Setup boxes are comparable in lead time to other rigid formats — the wrap-and-assemble cycle is well-established. Air freight (5–7 days) is available for urgent launches; sea freight (28–35 days) is standard and most economical. Sample production runs in parallel with the first week of bulk production.