Luxury rigid packaging
Rigid boxes are synonymous with luxury packaging. Whether used for influencer mailers, product launches, event gifting, or premium retail presentation, they’re designed to make a lasting impression.
At Progress, we’ve been creating bespoke rigid packaging for over 25 years helping brands elevate their unboxing experience through considered materials, construction, and design. From beautifully wrapped paper-over-board boxes to innovative eco-friendly V-FORM packaging, rigid boxes combine craftsmanship with structure to showcase your products in a truly premium way.
Step 1:
Format & Size
Getting started
Before delving into design and finishes, it’s important to establish the right format and size for your packaging. Consider what’s being packed, how it will be presented, and the best structure to complement your brand. Getting these fundamentals right will ensure your packaging feels intentional – not excessive – helping to minimise waste and maximise visual impact.
Start by measuring your product and thinking about how you want it to sit inside your rigid box. Once you’ve planned the layout, we can help define the internal size and calculate the outer box dimensions. Getting these basics right ensures your packaging fits perfectly, looks considered, and avoids unnecessary material waste.
Choosing the Right Format
Rigid boxes can be produced in various structural styles, each offering unique benefits for presentation, storage, and shipping. Popular formats include:
A simple, classic format with a separate lid and base. It’s ideal for timeless presentation, as seen in Verso Skincare.
A premium format featuring an inset shoulder that adds depth and contrast. This elegant design enhances luxury presentation, as used in the Wolfburn Whisky.
A wrap around design providing seamless protection with magnetic or tab closures. It delivers durability and a premium experience, as seen in Markus Lupfer.
A book-style, fully enclosed structure ideal for presentation and retail packaging. This format offers a luxurious reveal, demonstrated in the Side Story perfume packaging.
A slide-open format combining functionality and refinement. The tray glides smoothly into a sleeve, creating a premium experience like the Abel Discovery Set.
Cylindrical and durable, perfect for bottles, apparel, or rolled products. The Sunspel Eau De Parfum tubes showcase this simple yet striking style.
Built entirely to your specifications for a unique result. It allows complete creative freedom and bespoke features, such as Gordon & MacPhail
Step 2:
Fitments & Closures
Fitments ensure your items are protected and displayed neatly within the box. Closures enhance usability and complete the design.
Fitments
When designing the interior of your packaging, fitments play a crucial role in both protection and presentation. They keep products secure, enhance the unboxing experience, and can be tailored to reflect your brand’s sustainability goals or material preferences.
Provide strength, structure, and precise alignment while keee lined to keep materials consistent with the outer box. They’re ideal for premium or delicate products, maintaining visual harmony as seen in Abel – Layering Set.
Lightweight, cost-effective, and fully recyclable, making them a smart choice for e-commerce and retail. They protect products during transit without adding unnecessary weight or waste.
Custom-cut for precision and a smooth, professional finish that keeps fragile items secure. The AZNU phone box demonstrates how this material balances protection and presentation.
Precision-moulded to hold products securely while highlighting their form and contours. These trays can also be flocked to add a soft-touch, premium finish, as seen in Haberdashery’s sculpture packaging, creating a polished and refined internal presentation.
Made from moulded fibre for strong, eco-friendly protection with a natural texture. The Joan packaging project highlights how pulp fitments combine sustainability and visual appeal.
Soft, biodegradable, and tactile, can be die-cut to securly hold and provide natural cushioning for high-end items. As shown in Spitfire Audio’s packaging.
Folded or die-cut from paperboard to separate and organise multiple products within a box. used by Bath hosue to replace traditonal vac formed trays.
Post-Consumer Waste Fitments
Produced from reprocessed materials, including reclaimed recyclable foam, to create sustainable, cushioned inserts. This eco-focused choice reduces landfill waste while offering protective support for premium products. As seen in Surman Weston.
Created using mycelium, the root structure of mushrooms, these inserts are grown to fit your product perfectly. They’re fully compostable and offer strong, natural protection for environmentally conscious brands.
Loose, biodegradable paper or fibre used to cushion and stabilise items in transit. The Peet Rivko box demonstrates how void fill can enhance safety while maintaining environmental responsibility.
Closures
To secure and close your rigid box you may need to consider different closures
Provide a simple, clean method of closure that keeps your box secure while remaining easy to open and close, maintaining full recyclability. Victoria Beckham utlised this to make their packaging 100% recylable.
Add elegance while securing the box. Common in gift packaging and premium retail applications.
Provide a discreet and premium closure method. They’re popular for presentation boxes needing a smooth finish.
Step 3:
Process & Material
All rigid boxes begin with greyboard (also known as chipboard) — a dense, recycled board forming the box’s structural base. The construction method and chosen wrap material define the aesthetic, tactility, and environmental impact of your packaging.
Paper over board
The most popular production method, using die-cut greyboard wrapped in covering paper for limitless creative finishes. This approach allows for different textures, colours, and papers to bring your brand vision to life.
Natural, tactile papers like Colorplan or Wibalin, available in various colours and textures. They’re fully recyclable and perfect for a refined, minimal finish.
Papers with gloss, satin, or matt finishes for a sleek, durable surface. Ideal for retail packaging requiring visual clarity and resilience.
Eco-conscious options made from recycled content, such as Notpla or Cairn. They provide an authentic, sustainable aesthetic without compromising quality.
Specialist Papers & Creative Coverings
Encompassing metallics, fluorescents, linens, and textured coatings that deliver standout finishes with a tactile, premium feel. These materials, often sourced from suppliers like Winter & Company, are ideal for heritage brands, limited editions, or eye-catching promotional packs seeking a timeless, elevated aesthetic.
Custom dyed or Pantone-matched papers to achieve perfect brand consistency. These can be uncoated or coated depending on finish preference.
V-form
V-FORM simplifies traditional rigid box production by scoring directly into the board to create clean 90° folds. This reduces material use and improves recyclability while maintaining a luxury finish, making it a strong choice for sustainable packaging.
Premium chip board (Recycled / FSC Certified)
High-density, recycled boards with smooth surfaces for precision wrapping. Suitable for luxury presentation and detailed print applications, examples of this material include ESKA Board and Paperback.
Duplexed or Laminated Boards
Two or more layers bonded for added strength or thickness. Often used for heavy or multi-item packaging.
Recycled & Alternative Fibres
Papers made from grass, pulp, or alternative natural sources. These provide texture and eco appeal for environmentally focused brands.
Step 4:
Branding & Embellishments
Your box exterior is the first interaction customers have with your brand. Print and finishing techniques define quality, create emotion, and reinforce brand identity.
Print methods
Your print choices define how your brand comes to life across your packaging. The right process can elevate simple designs, highlight texture, and ensure colour consistency across every box and sleeve.
Delivers high-quality, full-colour prints with excellent detail. Perfect for intricate designs and brand consistency.
Applies bold, opaque colour layers ideal for minimal or textured surfaces. Best suited for shorter runs or speciality effects.
An eco-friendly option offering vibrant, durable colour. They reduce environmental impact without sacrificing finish quality.
Ensures brand colour consistency across packaging. Ideal for businesses needing precise brand alignment.
Finishes
Finishes add tactile quality and visual depth, transforming packaging from functional to memorable. They help communicate quality and enhance the perceived value of your brand.
Adds metallic or pigment foil for high-impact branding. Options include flat, embossed, or fluted foiling for texture and shine.
Creates tactile detail by raising or recessing designs. Often paired with foiling for premium definition.
Adds a gloss, matt, or soft-touch layer for durability and texture. It enhances longevity while maintaining a professional feel.
A clear coating applied to specific areas to highlight artwork. It adds contrast and depth, perfect for logos or key details.
Embellishments
Embellishments provide the final touches that personalise and refine your packaging. These elements add distinction, elevate unboxing experiences, and reinforce the craft behind your product presentation.
Offer a touch of luxury while improving functionality. Ideal for retail or gift boxes that demand a tactile opening experience.
Add seasonal or promotional messaging without redesigning the box. They can also add colour or branding contrast.
Provide extra dimension and brand distinction. They’re perfect for collector editions or high-value products.
Combine practicality with aesthetic appeal. Useful for transportable gift or retail packaging.
Showcase the product or design details inside. They increase visibility and enhance the unboxing experience.
