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Custom CDU Packaging Boxes

Confectionery, beauty and accessory brands use counter display units when a product has to win the last few seconds at the till. What matters most is how the tray, riser and header card share the weight of full stock, so we start from your filled unit count and counter footprint before quoting.

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What keeps a counter display unit upright once it is fully stocked?

Aly Packaging manufactures CDU packaging for UK confectionery brands, beauty and accessory labels, and suppliers to convenience stores and pharmacies. Most counter displays fail at the riser rather than the base. The front lip sags as stock is pulled, and the back panel leans under the header card. We fold the tray from E-flute or B-flute corrugated, double the side walls where the load sits and lock in a riser so rear rows sit higher. Header height is set against filled weight, because a tall card on a light tray tips forward. Send the filled weight; we draw the dieline.

The header card does the selling, so it carries one message

Shoppers see a CDU from above and slightly in front, usually while holding a basket or reaching for a card reader. The header needs the brand mark, one benefit and a price point, while the front lip repeats the product name once the first row has gone. Side panels are usually hidden by neighbouring stock, so print budget belongs on the header. Our proof shows the unit from counter height, so you can judge the sightline before printing.

A display that needs tape and a diagram rarely leaves the stockroom

Assembly is where many campaigns quietly fail. Staff rarely have time for instructions, so we design for one person and no tools: a crash-lock base that springs open, a riser that drops into pre-cut tabs and a header that pushes into a locking slot. Brands supplying many shops can go further. The outer shipper and display become one piece, with a perforated tear-off lid, so the unit arrives filled and goes straight onto the counter.

EPR reporting: counter displays count as packaging too

Leaving displays out of packaging data means under-reported tonnage and a later correction. Display units are treated as packaging by the UK Extended Producer Responsibility for Packaging Regulations 2024, and a CDU that groups sales units at the counter is normally reported as secondary, non-household packaging. Loose sweets on the tray also bring retained Regulation (EC) No 1935/2004 on food contact materials into play; wrapped bars do not. We record board grade, unit weight and coatings on the specification before production begins, so your return uses real figures.

Open tray, tiered riser or dispenser front?

Format follows how customers pick the product up. Open trays suit lip balms or chocolate bars taken by the handful. Tiered risers lift rear rows of taller tins or mini bottles into view. Dispenser fronts with a pull slot release sachets and blister cards one at a time, and divided inserts keep flavours or shades apart.

Materials

  • E-flute corrugated, around 1.5mm, for compact trays with fine print
  • B-flute corrugated, around 3mm, for heavier stock and taller risers
  • Folding box board for header cards and light inserts
  • Moisture-resistant liners for units near chillers or coffee machines

All materials are sustainably sourced, FSC-certified and comply with UK packaging regulations.

Finishes

  • Matte or gloss aqueous varnish against restocking scuffs
  • Gloss lamination on header cards that are handled often
  • Spot UV or foil on the logo, kept clear of price panels
  • Litho-laminated print for photographic artwork on corrugated

Each finish enhances both durability and visual impact, helping your display boxes attract attention and reinforce brand loyalty.

Why load-test a plain sample before printing?

An unprinted structural sample cut from the production board is the cheapest test a CDU can have. Fill it with real stock, pull the front row and leave it loaded overnight: any bowing at the lip or lean in the header shows up on your desk, not across a campaign. Printed prototypes follow once the structure holds.

Which details turn a CDU idea into a costed dieline?

Send unit dimensions and filled weight, the number of units per display, your target stores and the artwork. Confectionery brands, beauty labels, pharmacy suppliers and field marketing agencies then receive a recommended flute, riser and header layout, with material weights listed for EPR. Low minimum quantities let you trial a display in a few stores before a wider rollout. Standard turnaround is 10 to 12 business days from artwork approval, with a rush option in 6 to 8 business days. Contact us at sales@alypackaging.co.uk or call +447462212450.
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What Makes Us The Top Supplier?​

Top quality prints using the latest technology

We are commercial printers with experience in Litho,
Digital, and off-set printing techniques.

Fully Personalised sizes and designs

We specialise in manufacturing bespoke boxes in
custom size and shape of your choice.

Quick Turnaround

With our printing setups across the globe, we are
capable of handling small and bulk orders alike.

Flawless Finishing with Prime Results

Aly Packaging is mainly a B2B supplier, we believe in delivering the best of the best.

Dedicated Packaging Consultants

Our dedicated team of packaging consultants are
there to help you from start to finish.

Environmentally friendly production processes

Our eco- friendly cardboard, kraft, corrugated, and rigid boxes are produced in a controlled environment.

Customise Your Custom CDU Packaging Boxes

Select Key Features & Finishes

  • Dimensions
    Custom Sizes: We only manufacture bespoke boxes. You can order your custom printed boxes according to your preferred shapes and sizes.
  • Minimum Order Quantity
    MOQ: The minimum order quantity you can expect from us is 50 Boxes.
  • Paper Stock
    Paper Stock: 250Gsm to 500Gsm (14pt to 28pt) Eco-friendly White Card or Brown Kraft, B, C, or E-flute Corrugated, or 800Gsm to 1400Gsm Rigid Hardboard.
  • Printing
    Printing Method: 1-4 Colour CMYK or Pantone Colours - Off-set, Digital, or Screen Printing – Outside or Both Sides
  • Sampling
    Sampling: Free Digital Proofing. Material Sampling and Prototype Sampling is Provided on Demand.
  • Turnaround
    Production Speed: Standard 10 Business Days, Priority 8 Business Days, Rush 6 Business Days.

Rush Order Service

We truly understand that everything is not standard so our expedited plan of 04 working days is the solution to your rush requirements. Fill below form and get instant response from one of our packaging experts.

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