The creative process for custom-made packaging

The process of designing effective, attractive rigid packaging begins with an idea. We could start with your idea, or you can brief us to develop concepts from scratch.


Years of experience in the packaging industry has given us a wealth of design knowledge – our creativity is perfectly balanced by practical understanding.

CAD designs and virtual prototypes
Our designers use advanced 3D computer aided design (CAD) software. You’ll be able to see the designs from every angle – even sitting on the shelf. The level of detail provided by CAD images removes the need to create a physical prototype, although we can produce a real-life prototype if you require one.

Material choice

  • Our detailed knowledge of raw materials and production techniques ensures your packaging will be produced in the most appropriate material – for your purpose and your budget.
  • Food grade clear PVC can be used for food products where freezing is not involved.
  • Clear PET is the best choice for recyclability.
  • High Impact Polystyrene is ideal where there are any concerns about active ingredients or reactions.


Precision tooling

Once the virtual or physical prototype is signed off, we move to the tooling stage. Aluminium is our preferred tooling material, because it produces the best result at the best price. But we also use resin for tooling in situations where volumes are lower. Knife design is crucial where smooth edges are required. When tooling is complete, samples will be produced for your sign off.

“I worked with PlusPac for years, when I was general manager for LaBonne Cuisine. It was a great relationship, because PlusPac are very flexible and nimble. They could adjust production runs quickly and easily to suit us. If we misjudged purchasing cut off days or orders, they’d move quickly and get the stock we needed. PlusPac even labelled the lids for us, which saved on machinery costs.”

Barry Kitching,
former General Manager,
LaBonne Cuisine