Charger Packaging Boxes.

A fitted insert gives the adapter its own seat and the cable its own channel, so the two never touch in transit. Adapter pins scuff a coiled cable when the pair is loose, and a scuffed cable reads as a return even though nothing is broken. The insert is die-cut from the same boxboard as the carton or built as a separate tray, depending on the run.

We will not quote a loose-packed adapter and cable in one cavity. The scuffing is too predictable.

The certification zone is planned into the layout before any branding is placed. Electrical marks vary by market and take a fixed amount of panel space, so we block that area out first and fit the artwork round it. Adding marks late means shrinking a logo or moving a wattage callout at proof stage.

Tell us which markets the pack will sell in and we'll leave the right footprint clear on the dieline.

Folding boxboard for retail cartons, E-flute corrugated where the box also ships on its own, and rigid board for a premium tier. The grade is chosen from the weight of the charger rather than the size of the box. A charger is dense for its footprint, so the base carries more load than a carton this small usually sees.

A weight-rated base stops the bottom flap bowing on a shelf or in a mailer.

Full CMYK with the wattage figure set large is the usual retail spec. Buyers compare on wattage and compatibility first, so those read above the brand on the front panel. A matte lamination hides fingerprints on a premium tier, and soft-touch is available for higher-priced chargers.

Foil detail can pick out a logo, and a window option shows the adapter through the front if you want the colour visible.

Common sizes are 4 by 3 by 1.5 inches and 5 by 4 by 2 inches. We measure the adapter brick and the coiled cable separately and build the insert cavities from those, then size the carton round the insert. Every dimension is quoted as interior length, width and depth.

Hang-tab versions need a little extra height above the product for a reinforced tab.

The minimum run is 500 units. Pricing steps down at 1,000 and again at higher tiers, so it's worth asking for two quantities on the same quote. Retail and shipper formats are priced separately because they use different board.

Small runs can still carry a fitted insert. The tooling is simple and the insert cost is spread across the order.

Production takes 7 to 10 business days once artwork is approved. A rush run comes through in 5 to 7 business days when the schedule allows. Samples take 5 to 7 business days and are sent before bulk so you can test the adapter seat and cable channel in your hand.

The sample fee comes off the production order.

Yes, recycled-content board is the standard spec for this category. Folding boxboard and E-flute corrugated both come in recycled grades with a print surface good enough for full-colour retail artwork. Buyers in the electronics aisle expect it, and a recycled-content mark fits alongside the certification zone.

The fitted insert is board as well, so the whole pack goes into paper recycling once the window film is peeled off.