What Is the Minimum Order for Custom Printed Boxes?
Custom Packly UK Editorial Team
11 June 2026
The minimum order for custom printed boxes usually starts from 100 boxes, but the exact quantity can depend on the box type, material choice, production setup and the finish you want. For many startups and small businesses, 100 boxes is a practical first step because it allows you to test packaging without committing to a large production run.
At Custom Packly UK, many custom printed box orders can begin from 100 units, especially for mailer boxes, folding carton-style boxes, rigid boxes and food boxes. Some products, such as tubes, paper bags and certain luxury box styles, may need a higher minimum because the production setup or material sourcing works differently.
The important point is simple: MOQ is not just a random number. It is usually linked to how the packaging is produced.
Why Do Custom Printed Boxes Have a Minimum Order?
Custom printed boxes need setup before production begins. Artwork must be checked, dimensions need to be confirmed, materials are prepared, printing is arranged and the structure has to match the product. That setup takes time whether you order 20 boxes or 500 boxes.
This is why very small runs can become expensive per box. The setup cost is spread across the number of units produced. If the order is too small, each box carries a much higher share of that setup cost.
For example, if a business wants only 25 printed boxes, the print setup, material preparation and machine time may still be similar to a 100-box order. In that case, the smaller quantity does not always save as much money as expected. It may even make the per-box price feel too high.
That is why 100 boxes is often a better starting point. It keeps the order small enough for testing, but large enough to make production more practical.
Which Custom Boxes Can Start From 100 Units?
Many common custom box styles can usually start from around 100 units. This includes Mailer Boxes, folding carton-style packaging, Rigid Boxes and many food packaging options.
Mailer boxes are often suitable for ecommerce brands, subscription boxes, PR parcels and product launches. They are a strong option when a business wants custom printed packaging that can protect the product and still look presentable when delivered.
Folding carton-style boxes are usually a practical choice for lightweight retail products, cosmetics, skincare items, food products and small consumer goods. These sit under Custom Box Styles and Shapes, where structures such as tuck end boxes, auto bottom boxes, seal end boxes and gable boxes can be selected around the product.
Rigid boxes can also often start from 100 units, depending on the structure and finish. They are more premium than standard cartons, so the cost per box is higher, but they can still work for smaller runs when the product needs a stronger presentation.
Food boxes can also begin from 100 units in many cases. This is useful for restaurants, bakeries, cafés and food startups that want printed burger boxes, pizza boxes, fries trays, takeaway cartons or other branded food packaging without ordering thousands at the start.
Which Packaging Types May Need a Higher MOQ?
Some packaging styles may need a higher minimum order than 100 units. This often includes custom tubes, paper bags and luxury boxes.
Tube Packaging can need a higher MOQ because tube production usually involves different tooling, material preparation and finishing steps compared with flat carton structures. A candle tube, gift tube or cardboard tube with a lid may need more setup before production becomes cost-effective.
Paper Bags may also require a higher MOQ, especially when handles, special paper, large print coverage or luxury finishing are involved. A simple paper bag and a premium rope handle bag do not always follow the same production route.
Luxury boxes may also move above the standard 100-unit starting point when they involve special materials, detailed finishes, inserts, wrapping, magnetic closures or more complex production steps. The more specialised the build, the more important it becomes to check the MOQ before planning the order.
Why Production Setup Affects MOQ
The main reason MOQ changes is production setup.
Before custom printed packaging is made, the team has to prepare the structure, artwork, print method, material and finishing route. This can include dieline checks, colour review, board selection, print setup and finishing setup. If the box is simple, that setup is usually easier to manage at a lower quantity. If the box is complex, the setup becomes more involved.
Special materials can also increase MOQ. If a project needs a specific board, special paper, luxury covering, unusual colour stock or a less common finish, the material may need to be sourced or prepared in a larger quantity. This is why two boxes that look similar online can have different minimum order requirements in real production.
This is also why it is better to ask for a quote based on your exact size, material and quantity instead of assuming one MOQ applies to every custom packaging style.
Is 100 Boxes Enough for a Product Launch?
Yes, 100 boxes can be enough for a product launch when the goal is to test demand, check presentation and get real customer feedback before scaling. This is especially useful for startups and small businesses that do not want to tie up money in packaging before they know how well the product will sell.
A 100-box order can help you test how the packaging looks in photos, how customers respond to the presentation, how the box performs during delivery and whether the size feels right during packing. It gives you enough units to sell, sample or launch without making a heavy first commitment.
This works particularly well for skincare brands, food brands, candle brands, small ecommerce stores and local retail businesses. The first run does not need to be the final packaging system forever. It can be the first serious version that helps you learn what to improve.
Real Example: A London Skincare Brand Started With 100 Boxes
One skincare brand in London started with 100 custom boxes to test a new product. The first run helped them launch properly without taking on the risk of a large order. They could see how the packaging looked, how customers responded and whether the product had enough demand to justify a bigger production run.
The product became a huge hit.
After testing with 100 boxes, the brand started ordering around 10,000 boxes every month. That is the value of a low MOQ when it is used correctly. It gives a brand room to test first, then scale once demand is proven.
This is why small minimum orders matter. They are not only for businesses with small ambitions. Sometimes they are the starting point for much larger growth.
Does Ordering More Lower the Cost Per Box?
Yes, ordering more custom printed boxes usually lowers the cost per box.
A 100-box order can be a smart starting point, but it is not always the cheapest way to buy packaging. It is often the best route for testing, launches and smaller first runs. Once the product is selling consistently, larger quantities such as 250, 500 or 1,000 boxes can usually make the unit price more efficient.
This happens because the setup cost is spread across more boxes. Materials may also be purchased more efficiently and production time can be used more effectively. The result is usually a better per-box price.
So the better question is not only “What is the lowest MOQ?” It is also “What quantity gives the best value for where my business is right now?”
If you are testing a product, 100 boxes may be the right move. If you already know the product sells, a higher order may save money over time.
Should You Order Fewer Than 100 Boxes?
In most cases, fewer than 100 custom printed boxes are not the best route. It may sound cheaper at first, but the setup cost can make the per-box price too high.
If a customer asks for fewer than 100 boxes, the honest answer is that very small runs are usually expensive because the production still needs proper setup. Instead of paying too much for a tiny batch, it often makes more sense to start with 100 boxes and use the order properly.
You can use the first 100 boxes for product testing, launch orders, influencer gifting, photography, retail samples, market stalls, small ecommerce sales or customer feedback. That gives the packaging a real purpose instead of making the run too small to be useful.
Do You Need a Sample Before Ordering?
Not always.
For many straightforward custom printed box orders, a 3D mock-up is shown before production. This helps you review the look, artwork direction, structure and general presentation before the packaging is made.
Physical samples are more useful when the box is complex. If the structure is unusual, the product is fragile, the opening style is important or the packaging uses a special material or finish, a sample can help reduce risk before the full order.
For example, a complex rigid box with an insert may need more testing than a simple printed mailer box. A luxury product launch may also benefit from a physical sample because the touch, opening feel and insert fit matter more.
The key is to use samples where they add value, not as an automatic step for every simple order.
How to Choose the Right MOQ for Your Box Order
Start with the purpose of the order.
If you are testing a new product, launching a first version or checking how customers respond, 100 boxes can be a sensible starting point. It gives you a real production run without forcing you into a large commitment.
If your product is already selling well, ask for pricing at a few different quantities. Comparing 100, 250, 500 and 1,000 boxes can show you how much the per-box cost changes. Sometimes the jump to a higher quantity creates better value.
Also think about storage. A larger order may reduce unit cost, but it only makes sense if you have space to store the boxes and enough sales volume to use them. Packaging should support your business, not create pressure.
Before requesting a quote, try to prepare:
You do not need every detail to be perfect. Estimates are fine at the early stage. A good packaging supplier can help guide the structure, size and material once they understand the product.
Common MOQ Mistakes to Avoid
One common mistake is choosing the lowest possible quantity without considering the per-box cost. A low MOQ is useful, but it is not automatically the best value.
Another mistake is assuming every packaging style has the same minimum order. Mailer boxes, rigid boxes, food boxes, paper bags and tubes do not all behave the same in production. The structure and material can change the MOQ.
Some brands also wait too long to think about packaging. If you need custom sizes, special materials or a complex structure, leave enough time for design, mock-up approval and production. Rushing can limit your options or increase cost.
A final mistake is ordering before checking the real product fit. Always confirm the product dimensions, packed weight and any extra space needed for inserts, tissue, liners or protective material. A box that looks good but does not fit properly can create problems later.
Final Answer: What Is the Minimum Order for Custom Printed Boxes?
The minimum order for custom printed boxes is usually 100 boxes, especially for mailer boxes, folding carton-style boxes, rigid boxes and food boxes. However, some packaging types such as tubes, paper bags and luxury boxes may need a higher MOQ because of production setup or special material requirements.
For startups and small businesses, 100 boxes is often the best first step. It is enough to test the product, check the packaging experience and start selling without committing to a large order. Once the product is proven, ordering a higher quantity can usually reduce the cost per box.
If you are not sure what MOQ applies to your packaging, the best next step is to request a free quote. Share your product size, box style, quantity and artwork status, and Custom Packly UK can guide you towards the most practical starting quantity.