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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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

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

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

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

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

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.

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