Secondary packaging: cartons, rigid boxes & mailers Secondary packaging that sells, ships, and sustains.

Where brand identity meets real-world performance. Knockout sources secondary packaging from producers across North America using FSC/SFI-certified paperboard, low-VOC inks, and water-based coatings, produced as close as possible to your delivery location to keep lead times short and carbon footprint low.

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Format explorer

Pick your format. See exactly what we can do with it.

Tell us what the pack has to do and we will point to the right formats, or browse them all.

What is it for?

Folding Cartons

The workhorse of beauty and wellness packaging. Custom-designed to fit your primary packaging, communicate regulatory information, and create a branded moment at shelf or in the mailbox.

Materials: FSC/SFI-certified paperboard, recycled-content board, specialty stocks. All raw materials sourced within North America.
Print & finish: Offset lithography, low-VOC and vegetable-based inks, water-based coatings, spot UV, foil stamping, embossing, debossing, soft-touch, windowing
Customization: Custom structural design, inserts and fitments, Pantone matching, regulatory panel layout, barcoding and serialization
Best for: Unit cartons for skincare, cosmetics, haircare, supplements, fragrance, and lifestyle products

Spec this with us → Try the packaging selector

Rigid Gift Boxes & Kits

Luxury rigid boxes for kits, seasonal collections, gift sets, and elevated unboxing experiences, with custom inserts that keep products secure in transit while reducing breakage and operational waste.

Features: Magnetic closures, ribbon pulls, custom foam and paperboard inserts, modular tray systems, wrap-around printing, specialty papers and textures
Sustainability: Glueless tray systems and modular designs deliver a rigid-box experience using folding carton construction, cutting material waste and improving recyclability
Best for: Holiday kits, gift sets, launch boxes, subscription boxes, premium retail presentation

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E-Commerce Shippers

Corrugated shipping boxes engineered for the DTC journey, protecting your product through carrier handling while delivering a branded unboxing moment when it arrives.

Options: Custom-sized corrugated shippers, printed interiors, roll-end tuck-top and mailer-lock styles, protective inserts
Materials: Recycled-content corrugate, curbside-recyclable constructions
Best for: DTC orders, subscription shipments, multi-product kits, retailer replenishment

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Mailers

Lightweight shipping mailers for smaller DTC orders and individual product shipments. Choose all-paper padded formats for fully recyclable solutions, or bubble-lined mailers when additional cushioning is required.

Options: Paper-padded mailers (curbside recyclable), bubble mailers, custom sizes and branding
Best for: Single-item DTC orders, sample mailings, lightweight product shipments

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Labels

Custom labels for branding, regulatory compliance, and inventory management, both short-run digital and high-volume flexo production with fast North American turnaround.

Formats: Pressure-sensitive labels, shrink sleeves, wrap-around labels, tamper-evident seals
Print methods: Digital (short-run, fast turnaround), flexo (high-volume, cost-efficient), foil and specialty finishes
Sustainability: Recyclable pressure-sensitive labels with water-soluble adhesives that support cleaner material recovery
Best for: Primary container labelling, promotional stickers, compliance labels, serialization, inventory tracking

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Built to be recycled

What makes each format recyclable, and what to watch.

Recyclability is decided by the board, the inks, the coatings and everything you add to the pack.

Folding cartons

FSC/SFI-certified and recycled-content board, with low-VOC and vegetable-based inks and water-based coatings.

Watch forHeavy foil and laminated finishes can take a carton out of the recycling stream.

Rigid boxes

Glueless tray systems and modular designs give a rigid-box feel with folding carton construction.

Watch forAsk for the glueless tray option first. It cuts material waste and improves recyclability.

Shippers

Recycled-content corrugate in curbside-recyclable constructions.

Watch forSpecify recycled-content, curbside-recyclable constructions up front.

Mailers

All-paper padded formats are curbside recyclable.

Watch forBubble-lined mailers add cushioning but are not paper-only.

Labels

Recyclable pressure-sensitive labels with water-soluble adhesives that support cleaner material recovery.

Watch forChoose the adhesive and facestock together so the label stays recyclable.

Sustainable packaging guides →

How a pack gets to you

From dieline to delivery in six steps.

The same Knockout playbook runs every secondary packaging project.

Discovery We confirm the primary pack, shipping method and retailer rules before choosing formats.

Design Structure, dielines and regulatory panels are specced against your primary packaging.

Source Producers across North America quote to your budget, close to your delivery location.

Quality Control Proofs and samples are checked for fit, print and finish before production starts.

Production We check in production and before shipping, so defects surface while fixable.

Delivery Cartons, boxes and mailers arrive ready to pack, with freight handled.

Explore the Playbook →

Keep learning

Read before you order.

Damage Prevention by Design banner with a blue shipping box and corrugate graphic

July 21, 2026 Damage Prevention by Design: Corrugate, Inserts, and a Testing Plan How corrugate flute choice, inserts and dividers, and the right ISTA test work together to stop transit damage before your product ships. Read more →

Retail Readiness Checklist banner with a clipboard and barcode graphic

July 7, 2026 The Retail Readiness Checklist: Barcodes, Case Packs, Pallet Patterns, and Specs What retailers check at the distribution centre, from GS1 barcodes and pallet patterns to ISTA tests, and how to plan each item so shipments avoid chargebacks. Read more →

Woman looking at products on a retail shelf

November 7, 2024 Labelling in Sustainable Packaging Why shoppers struggle to tell genuinely sustainable products from greenwashing, and four labelling steps brands can take to make eco-claims clear. Read more →

Let's design something worth holding onto.

Whether you need a simple unit carton or a fully custom gift box with modular inserts, Knockout has the structural design expertise and manufacturing relationships to make it happen.

Book a discovery call →