Does Your Packaging Box Have a Smell? Is It Normal and What Odors Should Raise Red Flags?

Why does new packaging have a smell at all?

Let's start with the basics. Almost all manufactured products have a scent when they are fresh out of the factory. Your packaging is no different.

Cardboard boxes and printed rigid boxes are made from several components:

• Paper or paperboard (made from wood pulp).

• Printing inks

• Adhesives (glue that holds the layers together);

• Coatings, such as lamination films, varnishes, or UV coatings.

• Foam, fabric or other inserts may also be used.

Each of these materials contains chemical compounds that can release volatile organic compounds (VOCs). VOCs are carbon-based chemicals that evaporate at room temperature and create odour. Think of the 'new car smell' or the scent of a fresh book. That's VOCs.

In small amounts, these odours are completely normal and will typically dissipate within a few days to a couple of weeks, especially if the boxes are aired out.

Normal, Harmless Odours (Nothing to Worry About)

Below are the most common odours you might notice from new packaging that are not a cause for concern:

The 'paper' or 'cardboard' smell
A clean, earthy, slightly woody smell is perfectly normal. It comes from the lignin in wood pulp and the natural fibres of paper. If you’ve ever walked into a stationery shop or opened a new notebook, you will recognise this scent.

• How long it lasts: It usually fades within a few days.

• Is it safe? Yes. There are no health concerns.

The 'fresh print' smell
Printed boxes may have a mild, slightly sweet or chemical-like scent from the inks. Offset printing inks contain solvents and vegetable oils, such as soybean oil, which have a distinctive smell. This is normal for freshly printed materials.

• It lasts 3–7 days with good air circulation.

• Is it safe? Yes, for the trace amounts present on packaging. Modern printing inks are regulated and safe for most applications, including food packaging, provided they have the necessary certifications.

The 'glue' or 'adhesive' smell
The glue used to assemble boxes, especially rigid boxes and folding cartons, can have a noticeable odour. Water-based adhesives have a slightly sour, vinegary odour. Hot melt adhesives (the glue sticks used in glue guns) have a faint waxy or plastic odour.

• The smell lasts for 1–2 weeks, but improves faster with ventilation.

• Is it safe? Most adhesives used in packaging are non-toxic and safe. However, if the smell is extremely strong or stings your eyes, see the warning section below.

The 'lamination' smell
If your boxes have a gloss or matt laminate film (BOPP film), the lamination process uses heat and pressure to bond the film to the paper. Freshly laminated sheets can have a faint, plastic-like odour. This is usually very mild and fades quickly.

• It usually lasts 2–5 days.

• Is it safe? Yes. BOPP lamination is food-safe and widely used.

Odours That Should Raise Red Flags

While most packaging smells are harmless, certain odours indicate problems with the materials used, the manufacturing processes or the storage conditions. If you notice any of the following, contact your packaging supplier immediately and do not ship the boxes to customers until the issue has been resolved.

Strong, sharp chemical smell (like nail polish remover or paint thinner)

What it might be: High levels of solvents or VOCs from improperly cured inks or poor-quality adhesives. Some cheap inks use aggressive solvents that do not fully evaporate during production.

Why it’s a problem:

• These volatile compounds can migrate into food products, affecting their flavour and odour.

• Prolonged exposure may cause headaches, nausea or respiratory irritation.

• This indicates poor manufacturing quality.

What to do: Reject the batch. Ask your supplier to reprint using low-VOC or water-based inks. Although airing the boxes for several weeks may reduce the smell, it is a sign of a deeper quality issue.

Sour, rancid or 'vomity' smell

What it might be: This odour is often linked to butyric acid, which can be produced when certain water-based adhesives or coatings degrade. It can also come from recycled paper pulp that hasn’t been properly processed.

Why it’s a problem:

• This smell is highly unpleasant, and customers will certainly notice it.

• It can transfer to products inside, particularly paper-based items such as books, clothing or food.

• The smell often worsens over time rather than fading.

What to do: This is a defect. Return the boxes to your manufacturer. Do not try to mask the smell with perfume or deodorisers — that will just make it worse.

Fishy or ammonia-like smell

What it might be: This can come from certain adhesives, especially those containing casein (a milk protein) that has spoiled. It can also indicate mould or bacterial growth on the paper if the boxes were stored in damp conditions.

Why it’s a problem:

• Mould spores can pose a health risk, particularly to people with allergies or asthma.

• Ammonia-like odours from adhesives indicate that the adhesive has degraded and may fail (delamination).

• Customers will associate the smell with poor hygiene.

What to do: Inspect the boxes for visible mold (black, green, or white spots). If you see mold, discard the boxes immediately. If no visible mold but the smell persists, request a replacement batch.

Heavy, oily or 'diesel' smell

What it might be: Contamination during shipping or storage. The boxes may have been stored near chemicals, fuels or cleaning agents. Alternatively, mineral oil residues from printing inks used in the original waste paper may be retained by some recycled papers.

Why it’s a problem:

• Mineral oils can migrate into food and are considered a health risk by European food safety authorities.

• The smell is unpleasant and difficult to eliminate.

What to do: This is a serious quality and safety issue, especially for food or cosmetic packaging. Do not use the boxes. Demand a replacement from a cleaner supply chain.

Musty, mildewy or basement smell

What it might be: Moisture damage. The boxes were exposed to high humidity during storage or transit, which allowed mould or mildew to grow on the paper fibres.

Why it’s a problem:

• Mould is a health hazard.

• The smell is difficult to eliminate completely.

• The box's structural integrity may be compromised (weakened).

What to do: Check for visible staining or warping. If there is only a faint musty smell and no visible damage, leaving the box to air in a dry environment for a week may help. If the smell persists or there is visible mould, discard the boxes.

Why Do Some Boxes Smell Worse Than Others?

You might have ordered boxes from two different suppliers, and one supplier's boxes smelled much stronger. Here’s why:

Freshness off the press

Boxes that go straight from production into a sealed plastic bag or closed carton will have concentrated odours. Boxes that have been stored in a well-ventilated warehouse for weeks will smell much less.

Tip: Ask your supplier if they can 'air out' your boxes before shipping, especially if you need them to be odour-free on arrival.

Types of materials used

• Recycled paper often smells stronger than virgin paper because it contains a mixture of fibres and residues from previous uses.

• UV-cured inks have almost no odour because they cure instantly without solvents.

• Solvent-based inks have stronger odours, but are becoming less common.

• Water-based inks have mild odours, but are safer.

• Plastic inserts or foam may have their own chemical odours (off-gassing).

Storage conditions

Boxes stored in hot, humid warehouses will absorb moisture and may develop a mildewy smell. Boxes stored near chemicals, perfumes or cleaning supplies may also absorb these odours.

Shipping and packaging

If your boxes are shipped in plastic bags or shrink wrap, any odours have nowhere to escape. When you open the package, you will experience a 'burst' of concentrated odour. This doesn't necessarily mean the boxes are bad, just that they need to be aired.

How to Get Rid of Normal Packaging Smells

If you have boxes with a mild, normal odour that you want to eliminate before sending them to customers, here are several safe and effective methods:

Air them out (The best method)

The best method is to simply open the boxes and place them in a well-ventilated area. A room with open windows or a fan will speed up the process. Leave them for 3–7 days. For stronger smells, leave them for up to two weeks.

Pro tip: Separate the box components if possible (remove the lid and unfold any inserts). The more surface area that is exposed to the air, the faster the odour will dissipate.

Use baking soda

Place an open box or a bowl of baking soda near the stacked boxes (making sure they are not touching). Baking soda absorbs odours. Leave for 48–72 hours. You can also lightly sprinkle some baking soda onto a paper towel, wipe the inside of the box with it, then shake off the excess.

Activated charcoa

Activated charcoal bags (available online) are even more effective than baking soda. Place them in the box or near the stack for a few days. They capture VOCs and other odour molecules.

Sunlight and fresh air

On a dry, sunny day, place your boxes in the shade outdoors (direct sunlight can fade colours and warp paper). The combination of fresh air and UV light breaks down many odour-causing compounds.

Avoid masking smells

Never spray perfume, essential oils or fabric freshener directly onto packaging boxes. These add their own strong smells that can transfer to products and may cause allergic reactions. Plus, customers will wonder why their box smells like lavender.

How to Prevent Odour Problems – For Brands Ordering Packaging

The best way to deal with packaging odour is to prevent it from occurring in the first place. Here’s what you can do:

Ask the right questions before ordering:

• What type of inks do you use? (Do you prefer water-based or UV inks?)

• What adhesives do you use? Ask for low-odour options.

• Do you use recycled paper? If so, is it certified as having low VOC emissions?

• Can you air out my boxes before shipping?

Request samples and smell them.

When you receive a sample box (not just a digital proof), smell it. If the sample has a strong, unpleasant odour, the full batch will too. Wait a few days and smell it again. Good packaging should only have a faint, fleeting odour.

Specify odour requirements in your contract
For large orders, especially food, cosmetics or baby products, include an odour specification in your purchase order. For example: 'Finished boxes shall have no detectable off-odour when assessed by normal human olfaction.' This gives you legal recourse if the boxes arrive smelling bad.

Order your packaging well in advance to allow time for airing.
Don't schedule your product launch for the day your packaging arrives. Build in at least two weeks' buffer time. This allows you to air out the boxes if needed and avoids last-minute panic.

Conclusion

So, is it normal for a packaging box to have a smell?

Yes – a faint, papery, or mildly “new print” smell is completely normal and usually fades within days.

No – strong chemical, fishy, musty, or rancid odors are red flags. They indicate poor material quality, improper curing, contamination, or moisture damage.

As a brand owner, your packaging is the first physical contact your customer has with your product. A bad smell creates a negative impression that no beautiful design can overcome. But armed with the knowledge in this guide, you can distinguish between harmless temporary odors and genuine defects, take appropriate action, and ensure your customers only experience the joy of unboxing – not the shock of a stinky box.