Ceramic Mug Boxes.

The handle, almost every time, and the rim second. The handle is a thin arch that takes all the movement inside the box, and the rim is the thinnest section, so it chips at the corners. Neither failure is about board strength.

The cause is the mug moving. A snug cradle that holds the body and keeps the handle clear of every wall stops that, and loose fill in a plain box does not.

Moulded pulp for anything posted to a doorstep, die-cut board for retail distribution. The pulp cradle is formed to the mug shape and holds it immobile with the handle clear, which is the best protection there is. The die-cut insert is cheaper and fine for a gentler trip on a pallet to a store.

Putting a retail-spec insert in a posted mug box is the most common failure we see.

Individual cells, so no two mugs touch. Cell dividers in E-flute corrugated separate each mug, and the corners of the outer get their own cushioning because that is where a dropped parcel takes the impact. The handle of every mug still needs its clearance inside its cell.

Test the full assembly with mugs in it. A drop test on an empty box proves nothing.

Kraft board with simple flexo print for artisan and direct-to-consumer brands, and full CMYK for retail and gifting. A window panel is worth having, since on a printed mug the design is the whole product and the box should show it. Matte lamination is the premium finish for designer ranges.

Inside print is under-used. It is seen at the moment of opening, which is when a gift box does its work. Fragile marking for parcel networks is a practical addition.

A standard 11 oz mug takes a 4.5 by 3.5 by 4.5 inch box and a 15 oz mug takes 5 by 4 by 5 inches. Those are internal figures with the insert in place, and they change with the handle profile and the cradle depth. Tall or wide mugs get their own size.

Send the mug and we'll build the box around it rather than guessing from the capacity.

500 boxes, and the insert is included in that count. A moulded pulp cradle has its own tooling, so at the minimum quantity the die-cut board insert is the more economical route. Tiers above 1,000 bring both options down.

The largest single run we quote is 100,000.

7 to 10 business days for a standard run, and 5 to 7 business days when it is rushed. A sample comes in 5 to 7 business days, and we want you to load it with a real mug and drop it from waist height. If the handle survives that, the run goes ahead.

Sample fees are credited against the bulk order.

Yes, both the E-flute outer and a moulded pulp cradle are fibre, so the whole pack goes in paper recycling. A die-cut board insert is the same material as the box. The only parts that change that are a window film and a matte lamination, both of which are small and optional.

For a direct-to-consumer brand that gets asked about packaging waste, the pulp cradle is the answer that holds up, and it happens to be the stronger option too.