Packaging

We produce everything from folding cartons and rigid boxes through to labels, sleeves, and speciality packaging. Our capabilities include food-safe packaging (HACCP certified), retail-ready solutions and premium presentation boxes. Digital or offset, short-run or mass production - if it packages a product, we make it happen.

Our packaging services include:

• Structural design, including dieline creation and pre-production prototypes
• Creative design and artworking
• Interactive 3D proofing through our online platform
• Embellishments including foiling, embossing and spot gloss
• Digital and offset print
• Finishing, including die-cutting and glueing
• Stock management, including fulfilment, storage and logistics with a fully integrated customer-centric portal

Absolutely. Every packaging project starts with your specific needs - your product, your brand, your budget. We'll engineer structural solutions that work for your production line, your distribution network, and your customer's experience. Custom doesn't have to mean expensive; it means fit-for-purpose.

Yes - from spot UV and foiling through to embossing and die-cutting. We also offer variable data printing for personalisation and security features. We'll advise what adds genuine value versus what's just adding cost.

Lead times depend on final design and order volume; however, we’re inherently nimble and able to respond quickly. Our standard turnaround is approximately 4 weeks, with the flexibility to adjust production to support your timelines.

If you have urgent requirements, we’re happy to discuss options to accelerate delivery - we’ll do everything we can to keep things moving seamlessly.

Our comprehensive Quality Management System (QMS) is built on extensive industry expertise and aligned with ISO 9001 standards, supported by external auditing and robust governance. We manage the full end-to-end process in-house, from structural design, prepress and proofing through to printing, embellishing, die-cutting, and glueing. This ensures rigorous quality control and complete visibility at every stage. With tailored processes to meet customer and regulatory requirements, we confidently support high-integrity sectors including FMCG and Pharmaceuticals.

Blue Star maintains a robust certification framework to support high-integrity sectors, including HACCP certification in both Auckland and Wellington for compliant food and FMCG packaging production, ISO 9001-aligned quality systems audited by external consultants, and industry-leading sustainability credentials: Toitū Enviromark Diamond, Toitū Carbon Reduce (Scopes 1–3) and Toitū Carbon Compatible reporting. We are also certified to both major global forestry standards: FSC® Chain of Custody and PEFC™ Chain of Custody -ensuring responsible sourcing and full traceability of certified materials.

Colour accuracy is non-negotiable. We use spectrophotometric measurement, maintain climate-controlled print environments, and our press operators are G7 Master qualified. Translation: your brand colours will be spot-on, whether it's the first box or the fifty-thousandth.

We tailor MOQs to suit your needs, factoring in design, materials, and print processes. Whether you’re after a small test run or full-scale production, our technology allows us to deliver efficiently from low volumes through to millions, with the agility to scale as you grow.

We manufacture flexible fibre carton packaging locally at our Auckland, Wellington, Napier and Christchurch sites. We are also able to deliver indent packaging solutions sourced offshore.

Yes, we have three sites nationwide (Auckland, Wellington, Christchurch) with storage and logistics supported by our fully integrated customer-centric portal.