Custom Printed Carton for Designer Doorware

The TLDR (Too Long Didn’t Read) Version

Designer Doorware needed a carton that looked sharp, protected heavy hardware during transport, and could be assembled without glue. We delivered a flexo-printed, die-cut solution using water-based inks—flat-packed, easy to fold, and made entirely in-house in our Melbourne factory.

• Client: Designer Doorware – premium architectural hardware brand.

• Problem: Designer Doorware required packaging that aligned with their premium brand, protected metal components in transit, and eliminated the need for glue or complex assembly.

• Solution: Imperial Cartons produced a flexo-printed, die-cut carton using water-based inks. The design was built for quick folding, no adhesives, and full in-house production control from artwork to delivery.

• Outcome: Designer Doorware received a durable, brand-aligned packaging solution locally made by Imperial Cartons, easy to assemble, and ready to go straight from delivery to product packing without additional labour or steps.

Prefer the details? Read the full story here.

Designer Doorware is known for manufacturing high-end architectural hardware. Their products are precision-made, and the packaging needs to reflect that same level of quality. They came to us needing a custom carton that not only looked the part but could also be assembled easily and provide solid protection during transport. This project is a good example of how we manage the entire process in-house, from artwork through to the finished carton, helping to keep things as simple as possible for the client.

Step 1: Artwork & Printing Plate

Designer Doorware supplied their artwork and we dropped it into a digital template to check the scale and layout on the box. Once they approved the layout, we created a flexographic printing plate, also called a Stereo. It's a custom-made polymer plate used to transfer their design directly onto the board during printing.

This step sets the foundation for clean, consistent branding.

Step 2: Flexographic Printing

We use Flexographic printing for most of our custom work. It’s fast, clean, and cost-effective. The Stereo gets mounted to the printer, and we use water-based inks—which are safe, dry quickly, and environmentally friendly. As the board moves through the line, the artwork is printed directly onto it. That means we can print and manufacture the cartons in one continuous run, saving time and reducing handling.

Flexographic Printing Plate – Stereo

Die-Cutting Forme Setup

Step 3: Die-Cutting the Carton

Once printed, the board moves to die-cutting. We use a custom cutting forme to cut the exact shape of the box, including folds, flaps, and tabs. This box was designed to go together without glue, which makes it faster for Designer Doorware to pack and fulfil orders from their end. Supplied flat-packed, it’s efficient to store and easy to assemble.

Step 4: Quality Check & Delivery

Every carton goes through a visual check to make sure the print is spot-on and the cuts are clean. Once they pass, they’re flat-packed and shipped. The final result is a strong, well-branded box that doesn’t need adhesives or extra labour—ready to use straight out of the stack.

Need Something Built to Fit?

This project is just one example of how we approach custom packaging—practical, brand-aligned, and built with precision. If you need a carton that does more than just hold product, we’re here to help you get it right—from first layout to final delivery.

Explore what’s possible with fully in-house manufacturing, get in touch to talk through your next job.