Semi-Custom Packaging – the low-cost start-up solution

Posted on January 7, 2026
by Dennis Salazar

Historically each new year brings a surge in inquiries from people who want to create a new box for a start-up business they are launching or updating/replacing a current packaging design.

We believe the increase in people contacting us every January is a result of a new year commitment to finally launch the web-based business they have been dreaming about. And in some cases, they are planning to use an anticipated tax refund to help finance their objective.

Salazar Packaging – a leader in e-commerce packaging

Nationally, there are very few packaging producers who have helped launch as many start-ups as we have, essentially since e-commerce became the way to go to market. Those customers we have helped to get started range from very small home based, to now household names including mega success stories such as Harry’s, Madison Reed, and Warby Parker.

Here are a few things that make us so good at helping customers navigate the rough waters of change, at minimal cost or expense:

Our semi-custom approach

Two of the greatest initial expenses are printing plates and cutting dies. There is a good possibility the cutting die size you need is already in our stock cutting die inventory. Depending on artwork, most new cutting dies today are priced between $1,200 and $1,500, so using an existing die we provide can provide funds for other things, like print plates. This is especially true if you are considering multiple product configurations such as a two pack, three pack, etc.

Your graphic design will undoubtedly require new print plates costing between $500 to $800 per color, per side. The good news is we may be able to offer you a discount on them, usually determined by the initial order quantity. More good news- if you are considering a flood coat of edge-to-edge solid printing, we can usually do that for you by offering a matte print plates at no cost. Free is nice!

Free design work and test samples

We are surprised to find out that some companies charge over $200 per hour for design time. We rarely charge a customer to develop a design because chances are, we have already created a box for a similar if not identical application. It does not matter if you are shipping cologne, barbecue sauce, or kitchen knives, because we probably have a design on file that has been tested and improved over time.

Here is what we have learned over the course of the last eighteen years:

  • Mock ups and ship testing are the best and only way to make sure a packaging e-commerce structural design is right for any application. We know any product being shipped has to be immobilized to avoid damage, and replacement cost.
  • Full size, 3-D mock ups can show what your customer sees when their product arrives. As the old adage reminds us, you only have one chance to make a good first impression could not be truer. These mock-ups will prove invaluable to help you finalize your new look and can help determine copy size and location. Please take time to read the first related post below.

Launching a new company, product or packaging design does not have to be an expensive and gut-wrenching decision, if you have the right partner to work with. Take a look at our gallery and see the wide variety and quality of the work we have accomplished for others. What they all have in common is that they were quickly implemented at minimal cost.

Let us help you as well. Call us at 630-551-1700 or  contact us through this link. Our experienced, non-commission customer support team is waiting to serve you.

Related Posts:

https://www.salazarpackaging.com/balancing-protection-presentation-e-commerce-subscription-boxes/

https://www.salazarpackaging.com/the-high-cost-of-your-outdated-e-commerce-packaging-design/

https://www.salazarpackaging.com/beginners-guide-to-e-commerce-packaging-design/

http://www.salazarpackaging.com/5-packaging-services-for-cost-reduction/

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