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8840 N Ramsey Blvd, Portland, OR 97203
info@portlandboxes.com
Standard sizes don't fit everything. We design and source custom corrugated solutions tailored to your exact specifications.
Need a box that is 13.5 x 9.25 x 7 inches? We can source or cut-to-size boxes for your exact product dimensions, reducing material waste and shipping costs.
We assemble multi-item kits with boxes, inserts, dividers, and packaging materials. Perfect for subscription boxes, product bundles, and assembly operations.
Set up recurring delivery schedules for consistent box supply. We manage your inventory so you never run out, with volume pricing that improves over time.
Add your logo, handling instructions, or brand colors to boxes. Available on both new and select used boxes for a professional presentation.
Share your product dimensions, quantities, and any special requirements through our contact form or email.
Our team creates a custom packaging plan optimized for protection, cost, and sustainability.
We present the solution with samples when possible. You approve before we proceed.
We source or produce your custom boxes and deliver them on your schedule.
See how Portland businesses have used our custom packaging solutions to solve unique challenges, reduce costs, and improve their operations.
A Portland-based artisan candle maker was shipping 2,000+ orders per month in standard boxes with excessive void fill. Breakage rates were 4.8%, and packaging costs were eating into thin margins. The generic brown boxes did not reflect the premium brand image.
Portland Boxes designed a custom-sized box (6.25 x 6.25 x 4.5") that fits the candle jars with minimal clearance, eliminating the need for void fill. We added a corrugated partition insert for multi-candle orders and printed the brand logo in one-color flexo on the box exterior. All materials were sourced from recycled and FSC-certified stock.
A regional electronics distributor needed to ship 47 different product SKUs from a single warehouse. Standard box sizes resulted in dimensional weight surcharges from carriers because most products did not fill their containers. The team was spending 20+ minutes per shift selecting and assembling boxes.
We analyzed the entire product catalog and designed 8 custom box sizes that efficiently covered all 47 SKUs with less than 15% void space in any configuration. Custom die-cut inserts protect products without bubble wrap. Color-coded size labels speed box selection on the packing line.
A Portland farm-to-table meal kit company was using new, food-grade boxes in a single size for all deliveries. Smaller kits (2-person) had wasted space and required ice packs to compensate for poor insulation. Larger kits (6-person) barely fit and often burst during delivery.
Portland Boxes created 3 custom meal kit sizes (Small, Medium, Large) with double-wall construction for insulation and strength. We added a corrugated insulation liner system that reduces ice pack requirements by 40%. All boxes are printed with the company brand and compostable ink. Boxes are delivered weekly on a recurring schedule.
We can create boxes in virtually any dimension. Here are some of the most commonly requested custom sizes and their typical applications.
| Custom Size (L x W x H) | Wall Type | Min Order | Lead Time | Typical Application |
|---|---|---|---|---|
| 6.25 x 6.25 x 4.5 | Single | 100 | 5-7 days | Candle jars, small jars, cosmetics |
| 9 x 7 x 3 | Single (E-flute) | 250 | 5-7 days | Book mailers, flat products |
| 11 x 8.5 x 5 | Single | 100 | 5-7 days | Subscription boxes, kits |
| 13.5 x 9.25 x 7 | Single | 100 | 5-7 days | Electronics, specialty retail |
| 15 x 10 x 8 | Single / Double | 50 | 7-10 days | Small appliances, equipment |
| 22 x 16 x 6 | Double | 50 | 7-10 days | Flat-pack furniture, artwork |
| 28 x 6 x 28 | Double | 25 | 10-14 days | Mirrors, flat panels, screens |
| 36 x 12 x 12 | Single / Double | 50 | 7-10 days | Long items, tubes, rolled goods |
| 48 x 8 x 36 | Double | 25 | 10-14 days | Large flat panels, tabletops |
| Any dimension | Any | Varies | 5-21 days | Fully custom to your specifications |
Our volume programs are designed for businesses with recurring packaging needs. The more you commit, the more you save — and the better service you receive.
500+ boxes/month
1,000+ boxes/month
5,000+ boxes/month
20,000+ boxes/month
Transparent information about what to expect when ordering custom packaging from Portland Boxes.
| Service Type | Minimum Order | Lead Time | Setup Fee |
|---|---|---|---|
| Custom Size (cut from stock) | 25 boxes | 2-3 business days | None |
| Custom Size (manufactured) | 100 boxes | 5-7 business days | $0 - $50 |
| Custom Print (1 color) | 250 boxes | 7-10 business days | $75 plate fee |
| Custom Print (2-3 color) | 500 boxes | 10-14 business days | $75/plate |
| Kitting / Assembly | 50 kits | 3-5 business days | None |
| Custom Inserts / Dividers | 100 units | 5-7 business days | $0 - $25 |
| Volume Program Setup | 500/month commitment | 1-2 weeks to launch | None |
Lead times are estimates for standard orders. Rush orders available for an additional fee. Setup fees are one-time charges that do not apply to reorders.
Yes. Our most popular custom service is cutting used boxes down to a custom size. We take larger used boxes and trim them to your exact specifications, giving you the cost savings of used material with the fit of custom packaging. This service has a low 25-box minimum and a 2-3 day turnaround. For manufactured custom boxes (new material), the minimum is 100 boxes.
We recommend measuring your product at its widest, tallest, and deepest points, then adding 1-2 inches on each dimension for cushioning material. If you send us your product dimensions and weight, our packaging engineers will recommend the optimal box size, wall type, and cushioning solution. We can also work from product samples — ship us a unit and we will design the packaging around it.
Custom-cut used boxes are typically 30-50% less expensive than manufactured new custom boxes of the same size. The tradeoff is appearance — used custom boxes will be clean and structurally sound but may show prior printing or minor wear. For customer-facing applications where appearance matters, we recommend new custom boxes. For internal, storage, or shipping applications, used custom delivers excellent value.
Absolutely. For custom-cut boxes, we can produce 2-5 samples within 24 hours at no charge. For manufactured custom boxes, we produce die-cut samples that arrive within 5-7 business days. Sample cost is refunded when you place your production order. We strongly recommend testing samples with your actual products before committing to a full run.
We accept Adobe Illustrator (.ai), PDF, and EPS files with all fonts outlined and colors specified in Pantone (PMS) values. For simple logos and text, we can work from high-resolution PNG or JPEG files (300 DPI minimum). Our design team can assist with file preparation at no additional charge for orders over 500 boxes.
Yes. Our volume programs include inventory management where we maintain a rolling stock of your custom boxes in our warehouse. We monitor your usage patterns and automatically produce replenishment batches before you run out. This eliminates the need for you to store large quantities on-site and ensures you never face a stockout. This service is included at no additional cost for Professional tier and above.
Tell us what you need and our packaging engineers will design a custom solution optimized for your products, budget, and sustainability goals.