What materials are used for custom boxes with handles¹?

You have a beautiful, but slightly heavy, gift set. Watching a customer struggle to carry it out of the store is painful. Their awkward juggle undermines the premium experience you worked so hard to create.

Custom boxes with handles primarily use sturdy paperboard² or corrugated cardboard³ for the box structure. The handles themselves can be integrated (die-cut from the box) or attached, using materials like ribbon, rope, or plastic.

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A handle turns a package from a simple container into a portable, convenient product. From my years at Wansa Packaging, I've seen that a handle does more than just help a customer carry something. It elevates the entire product. A gift box with a handle⁵ is convenient for the customer, and because of this feature, it takes the box's quality to the next level . It's a small detail that makes a huge difference in perception and practicality.

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What material is used for a packaging box?

You're trying to explain your box idea to a manufacturer, but you keep saying "cardboard." You're not sure if that's the right term, making you feel less confident in your communications.

The two primary materials for packaging boxes are paperboard (or cardstock) and corrugated cardboard³. Paperboard is a single layer of thick paper, while corrugated has a wavy layer for added strength.

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Understanding the difference between these two materials was a breakthrough moment for me early in my career. It’s the key to matching the right box to the right job. A designer like Jacky knows that choosing between them depends on a balance of strength, weight, and the desired print finish. Each has a specific role to play in the packaging world. One is the artist's canvas, the other is the reliable protector.

Choosing Your Box Material

Material	Best For	Key Feature
Paperboard	Retail packaging, food boxes, cosmetic boxes.	A smooth, flat surface that is perfect for high-quality, vibrant printing.
Corrugated Cardboard	Shipping boxes, e-commerce mailers, retail displays.	An internal wavy layer (flute) provides excellent strength and cushioning for protection.

For a lightweight box of tea sold in a supermarket, we would use paperboard. For shipping that tea to the store, or for creating a box with an integrated handle⁶ to carry a heavier item, we would turn to corrugated cardboard³ for its structural integrity.

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How to make handles for cardboard boxes?

You know you want a handle, but you're not sure what your options are. You don't want to pick one that looks cheap or won't be strong enough to hold your product.

Handles are made in two main ways: die-cut directly into the box material (integrated) or attached as a separate piece. Attached handles, like ribbons or plastic, often create a more premium feel.

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When we make gift boxes with handles, our main choices are materials like silk ribbon⁷ or PVC handles⁸ . The choice really depends on the brand's image and the product's weight. An integrated handle⁶ is cost-effective and practical, often seen on "briefcase" style boxes for trade shows. But for a true gift experience, an attached handle is much better. It adds a touch of elegance and tactile quality that a simple cutout can't match.

Common Handle Types

• Integrated Handles: A die-cutting machine simply punches a handle shape out of the main body of the box. This is common on corrugated boxes. It's strong and efficient but offers a more basic look.
• Attached Handles: These are added to the box during assembly and signal a higher level of quality.
  • Ribbon Handles: Grosgrain or silk ribbon⁷ is threaded through holes or slots in the box. This creates a soft, luxurious feel⁹, perfect for fashion or cosmetic gift sets.
  • Rope Handles: Twisted paper or cotton rope gives a sturdy, often rustic or nautical, feel. They are very strong and comfortable to hold.
  • Plastic (PVC) Handles: These are molded for comfort and can give the box a modern, durable look. They click into place and are excellent for heavier items.

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What material is used to make a box?

You see the final box, but you're curious about the process. What are "paperboard" and "corrugated cardboard³" actually made from? Understanding the raw materials can help you make more sustainable choices.

Boxes are made from paper pulp¹⁰, which comes from wood chips or recycled paper products. This pulp is pressed and dried to create paperboard or linerboard, the fundamental components of all cardboard boxes.

Thinking about the journey from a tree to a finished box on a shelf still fascinates me. It’s a process of transformation. At its core, nearly every paper-based box starts life as cellulose fibers. These fibers are mixed with water to create a slurry called pulp. This pulp is then spread across giant screens and run through massive, heated rollers that press out the water and form it into giant rolls of paper. If it's made in a single, thick layer, it becomes paperboard. To make corrugated cardboard³, we take thinner rolls of this paper, called linerboard, and glue them to another roll that has been shaped into waves, the "fluting" or "medium." This simple sandwich construction is what gives a shipping box its incredible strength. It's a clever piece of engineering that turns simple paper into a durable protective structure.

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What material is commonly used for packaging?

You've been focused on the box, but you realize it's just one part of the puzzle. What other materials are out there, and where does your handled box fit into the overall picture?

Paper and cardboard are the most common materials for secondary packaging¹¹ (boxes). For primary packaging¹² (what touches the product), plastics, glass, and metal are also extremely common and essential.

A handled box is rarely the primary package. Its job is to carry other items. For instance, gift boxes with handles almost always contain a set of products, like a cosmetic series . This makes it easy for the customer to buy everything together . In this case, the plastic tubes and glass jars for the cosmetics are the primary packaging¹². The beautiful handled box that holds them all is the secondary packaging¹¹. It's important to see how these materials work together.

Common Packaging Materials

Material	Primary Role	Example
Paper / Cardboard	Secondary Packaging	A handled gift box, a shoe box.
Plastic	Primary Packaging	Water bottles, lotion tubes, shrink wrap.
Glass	Primary Packaging	Serum bottles, jam jars, wine bottles.
Metal	Primary/Secondary	Soda cans, cookie tins.

Thinking this way helps you, and a designer like Jacky, design a complete and effective packaging system from the inside out.

Conclusion

The materials for handled boxes range from simple cardboard to elegant ribbons and plastics. Choosing the right one adds crucial convenience for your customer and significantly boosts your product's perceived value and quality.

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