Cushion Packaging Boxes.

A vacuum compression bag sits inside an E-flute carton, cutting the shipped volume to a fraction of the loose size. Freight is billed on volume, so this is where the money is saved. The fill then needs hours to a day to recover, and the carton is sized for the compressed pack rather than the finished cushion.

Compression is a shipping tool only. Retail display cushions are packed full so they look full on the shelf.

Because a customer who opens a flat cushion assumes it is poor quality, so the recovery time is printed where they see it first. The note goes on the inside lid or the top of the compression bag, at the moment of opening. We won't quote a compressed pack without it.

A line about fill type on the same panel helps too, since that is how cushions are chosen.

E-flute corrugated for shipped packs and folding boxboard for retail cartons. The shipper outer is rated for bulky, low-weight items that get thrown around in a parcel network. The retail carton puts presentation first, with a clear window film panel and a reinforced carry handle for packs carried out of a shop.

Fabric needs air, so neither version uses an airtight liner.

Full CMYK room photography, kraft natural for minimal ranges, or a printed band round a plain carton. The band is the flexible option: one plain box, a different sleeve per cover design. A window or touch opening lets customers feel the fabric, which is what they buy on.

A care and fill panel carries the cover material and washing guidance in a set position.

Common sizes are 18 by 18 by 5 inches and 20 by 20 by 6 inches. Those suit the usual square cushion sizes with a little clearance so the cover isn't creased at the corners. Bulk multi-packs are sized to the stacked height of several cushions.

For compressed shipping, we measure the vacuum-packed bag and size a smaller shipper to that.

500 units is the minimum, whichever format you pick. The retail carton and the compression shipper are quoted as separate lines, and on both the unit price comes down as you order more. A window panel and a carry handle each add a small amount per box.

If you sell both online and in store, the two formats can share one artwork set.

Allow 7 to 10 business days for standard production after proof sign-off. A rush order is 5 to 7 business days, and samples take 5 to 7 business days as well. We'd sample the compressed version so you can see how a recovered cushion sits in the retail carton.

Whatever the sample costs is deducted from the bulk invoice.

The carton is fully recyclable board, and the compression bag is a separate plastic component that comes out first. Kraft natural with a printed band is the lowest-impact retail spec, since it avoids lamination and keeps the window small. E-flute and folding boxboard both go into paper recycling.

If you don't need compression, the pack is board and tissue only.