Cardboard Engineering Specialists

Cardboard engineering is about more than just cutting board to size. It’s about solving real-world packaging, display, and promotional problems with the right shape, the right material, and the right finish.

At Limehouse Board Mills, we’ve been crafting custom cardboard structures since 1860. Whether it’s a rigid point-of-sale unit, a fold-flat promotional stand, or a bespoke packaging insert, our team engineers each product from the sheet up.

If it’s made of cardboard, we can build it.

From CAD to Cutting Table

We don’t do generic. Every job starts with your requirements: shape, strength, print, assembly style, and environmental priorities. Then we build from there.

Our cardboard engineering services cover:

Retail POS units (folding and rigid)
Exhibition displays and pop-ups
Window displays and signage
Custom cartons and promotional packaging
Protective packaging inserts and liners
Bespoke fruit punnets, bakery boards, and patisserie packaging
Diecut, glued, moulded, or guillotined sheet formats

We combine design service, CAD prototyping, and in-house manufacturing. That means speed, flexibility, and complete control over quality, finish, and format.

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Designed for Use — Not Just Display

Whether your product is going into chilled storage, onto a retail shelf, or across an exhibition stand, we engineer it for the environment it’ll face. Every structure is prototyped, pressure-tested, and refined before it goes to full run. It’s built to do the job, not just tick the brief.

Moisture resistance

Grease barrier requirements

Weight and load-bearing properties

Transport footprint

Flat-pack assembly

Ease of branding across different versions

Real Engineering, Real Outcomes

Soap Pack Interleaves That Don’t Stick

A soap exporter needed sheets between bars, and the old solution allowed grease to seep through, causing the bars to stick and break. We developed a thin, white, grease-resistant board with anti-stick surfaces on both sides. It’s still in use today with no grease bleed, no waste.

Recyclable Handles That Replace Plastic

A retail potato supplier wanted to replace stitched-in plastic handles on paper sacks. We trialled multiple builds and engineered a strong cardboard handle that wouldn’t tear at the join. Fully recyclable. No tooling changes needed.

Diecut Reel Protection That Cuts Handling Time

One customer used plastic film and double-sided tape to protect product reels during crane lifting. We replaced it with a self-adhesive, diecut board panel, rigid enough to prevent scrape damage and quick to apply. Saved time, cut materials, and looked smarter.

Rigid Pallet Sheets That Prevent Damage

A powder chemical manufacturer was losing product in transit due to pallet compression and rubbing. We engineered thick, rigid cardboard sheets to act as interlayers, reducing movement and preventing bag rupture during export.

Luxury Bakery Boards On Tight Turnaround

A bakery launching a patisserie range needed premium packaging boards to spec, but off-the-shelf options weren’t cutting it. We built a solution to meet colour, shape, and structural needs, then delivered the full run in time for launch.

Moisture-Proof Fruit Punnets

Original diecut handles on our cardboard punnets were struggling in humid environments. We upgraded to a stronger, water-resistant board and reshaped the handle for faster assembly. Better performance, fewer returns.

Sustainability Isn’t an Afterthought

Sustainability is built into every part of our process, not tacked on at the end. We use:

Recyclable materials sourced responsibly
Lightweight boards to reduce shipping carbon
Greaseproof and moisture barrier coatings that avoid plastics
Sheet formats that minimise waste
Products designed to be recycled at the end of life

If your team is targeting low-waste, plastic-free, or carbon-reduced options, we’re ready to help you spec the right structure.

Designed to Be Assembled, Shipped, and Used — Not Just Admired

Our builds work for real-world use:

Flat-pack formats that ship easily
Quick assembly with no tools or extras needed
Strong enough to carry weight, light enough to move
Folding and rigid variants depending on the application
Modular designs for retail rollouts or multi-use events

Your cardboard structure isn’t just part of a display; it is the display, the protector, the first impression. We make sure it delivers.

Limehouse Board Mill lorry ready to make a delivery

Perfect for:

Retailers and visual merchandisers: Custom cardboard displays, window signage, and POS stands
Marketing teams: Promotional cartons, pop-up displays, and branded inserts
Product manufacturers: Rigid packaging structures and moisture-resistant solutions
Exhibition designers: 3D modular displays, free-standing signage, and event build-outs
Sustainability leads: Plastic-free, environmentally friendly materials with low-impact specs

Why Limehouse Board Mills?

From bespoke prototyping to large-scale manufacturing, our team works with your brand, application, and supply chain to get the structure right and delivered on time.