Paperboard Packaging and Folding Cartons
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Custom Paperboard Packaging That Sells Your Product Before It's Even Opened
RPI Graphic Data Solutions designs and produces award-winning paperboard packaging and folding cartons for CPG brands, retailers, and businesses of all sizes — with no minimums, sustainable options, and full in-house capabilities from structural design to delivery.
Awards & Recognition
- GMA Print Excellence Gold — Packaging 2023
- GMA Print Excellence Bronze — Packaging 2023
- GMA Print Excellence — Packaging 2021
- GMA Print Excellence Gold — 2024, 2025, 2026
Certifications & Credentials
- G7 Master Qualified Facility
- WBENC Certified Women-Owned Business
- 55+ Years in Commercial Print & Packaging
- Made in the USA — Cincinnati, OH
Packaging That Protects Your Product and Powers Your Brand
Your packaging is often the first physical interaction a consumer has with your brand. It needs to do a lot — protect the product, communicate your brand identity, stand out on a crowded shelf, and increasingly, tell a sustainability story.
At RPI, we’ve spent over 55 years helping brands do exactly that. Our expertise in paperboard substrates, print techniques, structural design, and retail environments means we bring both creative vision and real-world manufacturing knowledge to every packaging project. Whether you’re launching a new product, redesigning an existing package, or looking for ways to reduce packaging costs without sacrificing quality — RPI is the partner that makes it happen.
We work with consumer packaged goods brands, regional retailers, e-commerce businesses, and companies of all sizes. With both digital and offset printing capabilities, we offer the flexibility to produce short runs cost-effectively and scale up as your business grows.
Folding Carton Styles & Packaging Formats
RPI produces a wide range of folding carton styles and paperboard packaging formats. Whether your product needs a standard tuck-end carton or a fully custom structural design, we have the expertise and equipment to deliver it.
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Packaging Capabilities — Everything Under One Roof
RPI’s in-house capabilities cover the full range of what modern packaging requires — from structural engineering and creative design through specialty finishing and fulfillment.
Design & Structure
- Structural design & engineering
- Custom die-line development
- Packaging templates library
- Prototyping & mock-ups
- Brand asset management
- Versioning & multi-SKU programs
Print & Finishing
- Offset & digital printing
- Hybrid print workflow
- In-line gluing
- Die-cutting
- Specialty finishes
- 4-color & PMS color matching
Packaging & Fulfillment
- Folding cartons
- Blister packs
- Corrugate shipper boxes
- Contract packaging
- Kit-packing & fulfillment
- Recyclable & biodegradable options
Sustainable Packaging Solutions — Our Green Growth Commitment
Today’s consumers and retailers increasingly demand packaging that’s not just beautiful — it’s responsible. RPI’s Green Growth program reflects our commitment to sustainable printing and packaging practices at every stage of production.
Sustainable Materials We Offer
- FSC-certified paperboard (Forest Stewardship Council)
- Recycled content substrates
- Biodegradable paperboard options
- Soy-based and low-VOC inks
- Recyclable folding carton stocks
Our Environmental Practices
- FSC Chain of Custody certified
- Energy-efficient printing equipment
- Waste reduction and responsible disposal
- Can provide material certifications for your compliance needs
- Help brands meet retailer sustainability requirements
Whether you need FSC-certified paperboard to satisfy a major retailer’s sustainability requirements or want to explore eco-friendly ink and substrate options that reduce your environmental footprint, RPI can guide you to the right solution.
Proven Results: Packaging That Reduced Costs & Won Awards
CASE STUDY — Real Results for a Real Brand
The Challenge:
A Dayton-area client needed a cost-effective packaging solution for their Temp-N-Toss Forehead Thermometer product line expansion. Their existing packaging concept was not scalable within their budget, and they needed a partner who could redesign the package without sacrificing shelf appeal or brand integrity.
The Results:
- Complete package redesign delivered — new structure, updated graphics, enhanced shelf presence.
- 12.4% cost reduction vs. previous packaging concept (including packaging and assembly costs)
- Project recognized with a GMA Print Excellence Award — Packaging Category
- Scalable solution that supported the client's product line expansion goals
Why Brands Trust RPI for Packaging
- 55+ Years of Packaging Expertise — We’ve produced packaging for Fortune 500 brands and regional businesses alike. That breadth of experience means we’ve seen almost every challenge — and know how to solve them.
- No Minimum Order Quantities — Thanks to our digital and offset hybrid capabilities, we can produce short runs cost-effectively and scale up seamlessly as your volume grows.
- Brand Consistency Across Runs — Our G7 Master Qualified color management process ensures your brand colors are consistent across every print run, every time.
- Cost Optimization Expertise — We can evaluate your current packaging cost structure and recommend substrate alternatives, production method changes, or inventory management strategies that reduce cost without reducing quality.
- Award-Winning Quality — Our packaging work has earned Gold and Bronze recognition from the GMA Print Excellence Awards. When quality matters, RPI delivers.
- Compression Testing & Production Validation — We work with your production team to ensure proper testing is completed to meet your specs and tolerances, including compression testing for structural integrity.
Frequently Asked Questions — Paperboard Packaging
A: Paperboard packaging refers to boxes, cartons, sleeves, and other packaging structures made from thick paper-based material (paperboard). It is one of the most widely used packaging formats in the consumer packaged goods (CPG) industry, used for products including food and beverages, cosmetics and personal care, pharmaceuticals, household goods, electronics accessories, and promotional packaging. Paperboard offers an excellent combination of structural strength, printability, sustainability, and cost-effectiveness.
A: Yes — RPI has an internal design team and access to thousands of packaging templates. We can work from your existing brand guidelines and die-lines, or create a completely custom structural and graphic design if you’re starting from scratch. Our designers understand both creative impact and manufacturing requirements, so your packaging will look great and be producible efficiently.
A: Because RPI can print on both digital and offset production platforms, we do not have a minimum order quantity for most packaging projects. Short runs are produced cost-effectively on our digital equipment, while larger volumes leverage our high-speed offset presses. The most cost-effective production method for your project depends on factors including flat size, finishing requirements, and quantity — and our team will guide you to the right approach.
A: For projects that require design and a new die-line, a typical timeline is 6 to 12 weeks from kickoff to delivery. If you already have an approved die-line and print-ready art, timelines can be significantly compressed — sometimes to just a few weeks. RPI’s in-house production model helps us move faster than multi-vendor programs, and we work with clients to accommodate tight deadlines when needed.
A: RPI works closely with your production team to validate that packaging meets your specifications and tolerances. This includes compression testing for structural integrity, substrate testing for compatibility with your filling or assembly lines, and digital and press proofing to verify color accuracy and print quality before full production runs begin.
A: RPI’s facilities are not FDA-certified for direct food contact packaging. However, we can produce folding cartons for secondary food contact applications — meaning the packaging that surrounds a food product but does not come into direct contact with the food itself. If you have specific food-contact requirements, our team can discuss your application and advise on appropriate solutions.
A: Yes. RPI uses gang-run printing and digital/offset hybrid methods to produce multiple package versions cost-effectively, even in smaller quantities. This is especially valuable for brands with regional variations, multiple SKUs, seasonal packaging, or test-market programs where volume is limited.
A: Yes. RPI offers a wide range of recyclable and environmentally friendly substrates for paperboard cartons. We use FSC (Forest Stewardship Council) certified products, meaning we can supply packaging made from responsibly sourced materials. Our Green Growth program reflects our broader commitment to sustainable printing and packaging practices, including the use of soy-based inks, energy-efficient equipment, and waste reduction throughout our production process.
A: Yes — cost optimization is one of the most common requests we receive. RPI can evaluate your current packaging specifications and cost structure, then recommend alternatives such as different substrates, adjusted structural designs, alternative finishing methods, or changes to production scheduling that can meaningfully reduce per-unit packaging cost without compromising your brand presentation or product protection.
A: Yes. RPI can identify which PMS colors can be closely matched using 4-color process printing, which can reduce costs on projects that would otherwise require additional spot color plates. We validate color accuracy through digital proofing and press proofing, and our G7 Master Qualified color management certification ensures consistent, accurate color reproduction across runs.
Ready to create packaging that earns its place on the shelf?
Let’s build packaging that protects your product, elevates your brand, and works within your budget.