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Understand the true cost of custom packaging at different quantities. See how setup fees affect your per-unit cost and find your optimal order size.
Order 500 more units to unlock 25% volume discount
See how your per-unit cost drops as order quantity increases
| Quantity | Volume Discount | Unit Cost | Setup Fee | Total Cost | Effective $/Unit |
|---|---|---|---|---|---|
| 100 | — | $2.65 | $250.00 | $515 | $5.15 |
| 250 | -10% | $2.40 | $250.00 | $850 | $3.40 |
| 500 | -18% | $2.20 | $250.00 | $1,350 | $2.70 |
| 1,000 | -25% | $2.02 | $250.00 | $2,275 | $2.27 |
| 2,500 | -32% | $1.85 | $250.00 | $4,875 | $1.95 |
| 5,000 | -38% | $1.70 | $250.00 | $8,750 | $1.75 |
| 10,000 | -45% | $1.52 | $250.00 | $15,500 | $1.55 |
Lower bars = better value per unit
Setup fees cover one-time costs like die creation (cutting shapes), printing plates (for flexo/offset), screen setup (for apparel), or digital file preparation. These fees are amortized across your order— larger orders mean lower per-unit impact.
Digital printing has low/no setup fees but higher per-unit costs—ideal for 50-500 units. Offset/flexo printing requires plates ($200-$500+) but delivers much lower unit costs at volume. The crossover point is typically 500-1,000 units.
Ask suppliers about: tooling/die charges, plate fees, minimum run charges, shipping estimates, and revision fees. A low per-unit quote can hide $500+ in setup costs. Always request "landed cost" including all fees and shipping.
If you'll reorder within 12 months, consider ordering at the next price break. Storage cost is usually cheaper than paying higher per-unit prices twice. Calculate: (extra units × unit cost) vs. (reorder setup + higher unit cost later).