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Frequently Asked Questions

Getting Started

How does the custom packaging process work from start to finish?

We make it straightforward. First, you’ll connect with our team to discuss your needs: what you’re packaging, your design vision, and your timeline. From there, we create CAD drawings of all components and work with you on material selection. Next comes the prototype phase, where we produce a sample that’s 95% true to your final production. This means you can actually see and feel what you’re getting before we move forward. Once you approve the prototype and finalize artwork, we move into production. If you need it, we can also handle assembly, shrink wrapping, and fulfillment so your packaging arrives ready to ship to your customers. 

What's the typical turnaround time for prototypes and production runs

Prototyping happens quickly; That’s one of our specialties. Our digital manufacturing capabilities mean we can turn around prototypes without the lengthy die creation process that traditional methods require. For production timelines, it depends on the complexity of your project, the quantity, and current production schedules. The best approach is to discuss your specific deadline with our team upfront. We’ve built our operation around speed to market, and our in-house capabilities give us more control over timelines than companies that outsource components. 

What information do you need from me to provide an accurate quote?

The more details you share, the more accurate we can be. Ideally, tell us what you’re packaging (dimensions, weight), your quantity needs, any special features you’re envisioning (magnetic closures, custom inserts, foil stamping), and your timeline. If you have reference images or examples of packaging styles you like, that helps too. Even if you’re early in the process and don’t have everything figured out, reach out anyway! Our team can guide you through the options and help narrow down what makes sense for your product and budget. 

What file formats do you accept for artwork?

We work with industry-standard formats including Adobe Illustrator (AI), PDF, and EPS files. Vector files are preferred for logos and graphics to ensure the highest quality output. For complex projects, our design team can provide you with templates that show exact dimensions, bleed areas, and fold lines. If you’re not sure whether your files will work, send them over. You can also review them against our Art Prep Checklist to ensure your files are set up correctly. 

Capabilities & Manufacturing

Can you manufacture all the components for my project, or will I need multiple vendors?

We manufacture as much as possible in-house, which is one of our biggest advantages. Our 200,000 square feet of manufacturing space houses everything from rigid box lines and die cutters to digital printing presses and foil stamping equipment. For something like board game packaging, we can produce the game boards, playing cards, printed rules, inserts, and boxes—then assemble and shrink wrap everything so it ships to you ready for retail. There might be specialty components (like custom game pieces) where we partner with trusted manufacturers, but we coordinate that for you. One point of contact, one cohesive solution. 

How does your digital manufacturing process benefit my project?

Digital manufacturing changes the game in a few key ways. First, there are no dies or plates to create, which eliminates both cost and time upfront. Second, you can make last-minute changes without starting over. Third, we can produce exact quantities, whether that’s 50 or 5,000, without the traditional pressure to order more to justify setup costs. Fourth, intricate laser cuts and complex designs that would be difficult or impossible with traditional die cutting become achievable. If you’re testing a new product or personalizing packaging for different retailers, digital gives you flexibility that traditional manufacturing simply can’t match. 

What industries do you work with most, and does that affect turnaround times?

We work across many industries—playing cards and gaming, wine and spirits, healthcare and pharmaceutical, vinyl records, subscription boxes, and more. We also produce sales kits for architecture, flooring, and building materials companies, plus luxury packaging for cosmetics. We don’t prioritize one industry over another when it comes to production schedules. What matters more is project complexity, quantity, and timing. That said, our experience in your industry often means we can anticipate needs and offer solutions that work specifically for your market. 

Do you offer sustainable or eco-friendly packaging options?

Yes, sustainability is increasingly important to our clients and to us. We work with recyclable materials, FSC-certified papers, and can help you explore options that reduce environmental impact without compromising quality or protection. The conversation usually starts with understanding your sustainability goals and any certifications you need, then we identify materials and construction methods that align with those objectives. Digital manufacturing also reduces waste compared to traditional methods since we’re not producing dies or running excess quantities “just in case.” 

Ordering

Do you have minimum order quantities?

No minimums. That’s a big part of what makes us different. Our digital printing and manufacturing technology allows us to economically produce short runs under 100 pieces or scale up to hundreds of thousands for large production runs. Whether you’re testing a new design before committing to a full production run or need just 50 sample kits for your sales team, we can help. This flexibility is especially valuable for seasonal products or limited releases where you need exact quantities without overproducing. 

How does pricing work for small runs versus large production orders?

Our digital manufacturing capabilities mean you’re not paying for die creation or absorbing high setup costs, which makes smaller quantities much more economical than traditional methods. As quantities increase, per-unit costs typically decrease, but you’re never forced to order more than you need just to hit a price break. When we quote your project, we’ll show you pricing at different quantity levels so you can make the decision that works best for your business. The goal is to give you flexibility without penalizing you for ordering what actually makes sense.

Fulfillment & Logistics 

What if I need a large production run but don't have warehouse space to store everything?

That’s where our warehouse and release program comes in. We can produce your full order to capture volume pricing, store it in our facility, and ship quantities as you need them—either to you or directly to your end customers. This is especially useful for seasonal products, subscription boxes, or when you want the cost savings of a larger run without tying up your capital or warehouse space. We handle the inventory management and fulfillment logistics. 

Can you ship directly to my customers or multiple locations?

Absolutely. Whether you need us to ship your full order to one location, split shipments to multiple distribution centers, or fulfill individual orders directly to your end customers, we can handle it. This is particularly helpful for subscription box companies, retailers with multiple locations, or businesses running promotional campaigns. We coordinate the logistics so you can focus on your business rather than managing shipping and fulfillment. 

What happens if something is damaged during production or shipping?

Quality control is built into every stage of our process, and issues are rare; but if something does happen, we take care of it. If damage occurs during production, we catch it before it leaves our facility and reproduce what’s needed. If damage happens during shipping, we work with you to resolve it quickly. Our goal is always to deliver exactly what you expected, when you expected it. We’ve been doing this since 1977, and our reputation is built on making things right. 

Design & Prototypes

Can you work with my existing design, or do I need to start from scratch?

Both. If you have artwork ready to go, we can work with that—we’ll just need to review it against our Art Prep Checklist to ensure it’s production-ready. If you’re starting with just a concept or need design help, our experienced graphic design and product development team can take it from there. We’ve created everything from complex multi-compartment game packaging to innovative wine boxes with unique constructions. Tell us what you’re envisioning, and we’ll figure out how to make it real. 

What happens if I need to make changes after seeing the prototype?

That’s exactly why we prototype. If something’s not quite right, we make adjustments. One advantage of our digital workflow is that changes don’t require creating new dies or plates, which traditionally meant significant time and cost. We can make revisions and produce updated samples relatively quickly. We want you to be confident in what you’re getting, so we work through iterations until the prototype meets your expectations. 

How do you handle rush projects or tight deadlines?

We’re upfront about what’s realistic. Some projects can move faster than others depending on complexity and what’s currently in production. Our digital capabilities give us more flexibility than traditional manufacturing. There’s no die creation time, and our quick make-ready equipment means faster setup. The key is communicating your deadline from the start. We’ll tell you honestly whether we can meet it and what options exist to expedite the process. We’ve handled plenty of time-sensitive projects, but setting clear expectations from day one helps everyone succeed. 

Will I get updates throughout the production process?

Absolutely. We don’t believe in going dark once production starts. You’ll have a dedicated contact who keeps you informed at key milestones—when production begins, when any issues arise that need your input, and when your order is ready to ship or be picked up. If you want more frequent updates or have specific checkpoints you’d like us to hit, just let us know. The more complex the project, the more important communication becomes, and we take that seriously. 

Why Choose NAPCO

What makes NAPCO different from other packaging manufacturers?

A few things set us apart. First, we’re family-owned and have been for nearly 50 years, which means we’re invested in long-term relationships, not just transactions. Second, our digital manufacturing capabilities put us in the top 1% of the industry. We can do things most manufacturers simply can’t. Third, everything happens in-house at our North Carolina facility, giving us control over quality and timelines that companies relying on overseas production or multiple vendors don’t have. Fourth, we actually enjoy solving complex packaging challenges. If you come to us with something unusual or technically difficult, that’s the kind of project that gets us excited. We’re not just manufacturing boxes, we’re partnering with you to create packaging that works as hard as you do. 

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