Behind A Potters Rigid Box

The Excellent Craft of a Rigid Box

Did you know that many of the boxes we offer are proudly made right here in the UK? At our Box Makers in Kidderminster, we meticulously craft rigid boxes using traditional manufacturing methods. We believe in the importance of local production and supporting British industries.

In this short blog post, we want to take you behind the scenes and provide some insight into the meticulous process involved in creating a Potters box. We specialise in manufacturing different types of rigid boxes, including presentation boxes, shoulder boxes, and hinged boxes. Although they vary in design, all of our boxes go through a series of similar processes to ensure exceptional quality.


It all starts with sourcing the finest materials from within the UK. The core components of our rigid boxes are paperboard and paper, which are responsibly obtained. These materials are carefully selected to meet our strict standards of durability and sustainability.

Rigid Box Paperboard
box image


Once we have the materials ready, the paperboard is precisely cut to size and indented to facilitate folding into its final shape. This needs to be done with both the lid and base or bases if it's a hinged or shoulder box, which has two bases.


Rigid Boxes Paperboard
box image


The next step involves skilful craftsmanship, as the cut paperboard is folded together to form the structure of the box. Both the lid and base (or bases, in the case of hinged or shoulder boxes) undergo this process, gradually giving shape to the boxes. The meticulous attention to detail ensures that each box is sturdy and visually appealing.

box image


With the rigid boxes taking form, they are then delicately wrapped in high-quality paper and securely glued holding the base of the box together and the same is done for the lid. For simpler presentation boxes, this step brings them close to completion. However, for hinged and shoulder boxes, additional work is required. The bases are carefully secured together, and a paper hinge is precisely fitted onto the hinged boxes.

Rigid Boxes Paper
box image


If the boxes require additional padding or protection, we seamlessly fit foam inserts or Courtelle wadding to ensure that the contents remain safe during transit. For bespoke rigid boxes, we go the extra mile to add those special finishing touches that make your packaging truly unique. Options such as foam, card, satin lining or carefully placed tissue paper are thoughtfully added to enhance the unboxing experience.

Rigid Boxes Inserts
box image


Once the boxes have undergone their final assembly, they are meticulously inspected to ensure they meet our stringent quality standards. After passing this rigorous evaluation, they are packed and sent to our main warehouse located in Norfolk, ready to be bought in stock form.

Rigid Boxes Packed
box image


If you choose to have your boxes branded, they are handed to our all-female printing team and either printed with hot foil or debossing. With their expertise, your boxes can be elegantly personalised using techniques such as hot foil printing or debossing. These methods involve the application of heated pigments, which are stamped onto the lid of the box, leaving behind a stunning design. It's important to note that this branding process does not compromise the recyclability of our boxes.

Rigid Boxes Printing
box image


Finally, with everything in order, the boxes are carefully packed once again and made ready for collection by our trusted courier. From there, it's only a matter of time before your new packaging arrives at your doorstep, eagerly awaiting to showcase your products or treasures.

Rigid Boxes 8
box image

At Potters, we understand the value of time. We strive to provide efficient service without compromising on quality. For our stock lines, we maintain sufficient stock levels, allowing us to deliver unprinted boxes in less than a week. If you prefer printed boxes, we can have them ready for you in approximately 2 weeks. However, please keep in mind that bespoke boxes, crafted with utmost love and care to meet your unique requirements, may require the full 8-week lead time. Rest assured, the end result will be well worth the wait.

Ready to embark on your packaging journey

We stock rigid boxes in all shapes and sizes. Discover our entire rigid box collection.


Shop Rigid Boxes