Choosing the right packaging order can be a balancing act. On one hand, customers expect packaging that feels personal, premium, and aligned with your brand. On the other, businesses need to manage costs, lead times, and inventory efficiently. This is where the decision between short run packaging and bulk orders becomes critical.
At Boxes To Go, we work with businesses at every stage, from startups testing their first custom boxes to established brands ordering high volumes of custom shipping boxes. Each approach has its own advantages, and the right choice depends on your goals, budget, and demand. In this post, we break down the differences between short runs and bulk orders to help you decide which advanced packaging solution is best for your business.
What Is Short Run Packaging?
Short run custom packaging is designed for flexibility. It allows businesses to order smaller quantities of custom packaging, often with lower minimum order quantities (MOQs), making it ideal for brands that want to move quickly or test new ideas.
Customers want packaging that feels personal and memorable, while brands are focused on controlling costs and delivery times. These goals might seem at odds, but advances in packaging technology have made it possible to achieve both.
At Boxes To Go, we’ve invested in the IECHO SKII digital cutting table, an innovative solution that allows us to produce short run flexible packaging, product boxes, and personalised shipping boxes without long lead times or expensive tooling.
How the IECHO SKII Improves Short Runs
Traditional packaging production often relies on die tooling, a slow and costly process used to cut and shape cardboard boxes. The IECHO SKII replaces this with high-precision digital cutting and automation.
This technology:
- Cuts, creases, and converts materials with speed and accuracy
- Reduces setup costs and production time
- Delivers consistent quality, even for small or one-off runs
- Makes ecommerce mailing boxes and custom shipping boxes faster and more affordable
The result is faster turnaround times, lower upfront costs, and the flexibility to produce short runs or personalised designs without compromising on quality. Using this technology, we were able to create a single custom box within a 24-hour turnaround for Matcha Made after they received a special order from Chris Hemsworth.
Alt text: Short run flat art for Matcha Made
What Are Bulk Orders?
Bulk orders involve producing large quantities of custom boxes in a single production run, typically once demand is well established. This approach prioritises efficiency, cost savings, and consistency across your custom packaging. A well-known example is Coca-Cola’s “Share a Coke” campaign, which used variable data printing to personalise labels at scale, producing over one billion packages across multiple regions.
By spreading setup and production costs across thousands of units, bulk orders significantly reduce the cost per unit. This makes them a strong choice for businesses with predictable sales volumes and established product lines.
Bulk ordering is commonly used for:
- Core product ranges
- High-volume ecommerce packaging
- Brands requiring strict consistency across all custom packaging
Short Run Packaging for Startups and New Brands
For startups and emerging brands, short runs offer flexibility and reduced risk. When demand is still uncertain, committing to large volumes of custom packaging can tie up valuable capital and storage space.
Why Short Runs Make Sense Early On
Short run packaging is ideal for:
- New product launches
- Seasonal or limited-edition collections
- Testing designs, colours, or messaging
Benefits include:
- Lower upfront investment
- Faster access to custom shipping boxes and product boxes
- Ability to make changes without wasting old stock
- Less storage required
While the cost per unit may be higher than bulk orders, the flexibility and reduced risk often outweigh the difference, especially in early growth stages.
Bulk Orders for Established or Cost-Sensitive Brands
Once demand is proven and sales volumes are predictable, bulk orders become strategically advantageous. Higher MOQs allow brands to achieve lower per-unit pricing, improving margins and supporting competitive pricing.
Established brands often choose bulk production for:
- High-volume ecommerce packaging
- Long-term product lines
- Large-scale custom shipping boxes
Choosing the Right Packaging Solution for Your Business
There’s no one-size-fits-all answer when it comes to custom packaging. The right solution depends on where your business is today and where it’s heading.
- Short run custom packaging offers flexibility, speed, and lower risk
- Bulk orders deliver cost efficiency, consistency, and scalability
- Both approaches can support high-quality ecommerce packaging when executed correctly
At Boxes To Go, we specialise in both short runs and bulk orders, offering advanced packaging solutions tailored to your needs. Whether you’re looking for personalised shipping boxes, ecommerce mailing boxes, or high-volume custom shipping boxes, we can help you find the right balance between flexibility and efficiency.
Final Thoughts
Choosing between short runs and bulk orders isn’t about which option is better, it’s about which one works best for your business right now. Short runs give you freedom to test, adapt, and grow, while bulk orders help established brands optimise costs and scale confidently.
If you’re unsure which approach is right for you, our team is here to help. Get in touch with Boxes To Go to discuss your packaging needs and discover how our flexible, custom solutions can support your business at every stage.