Chocolate Subscription Box.

We pair an insulated liner with phase-change or gel coolants in the warm months. Chocolate starts to bloom above 78°F, and the steady storage window is roughly 65 to 70°F, which a mailer exceeds for much of the year.

Packaging only does part of the work. Dispatch early in the week so boxes don't sit in a depot over a weekend, and in the hottest weeks many programs pause the send and explain why rather than risk a bloomed arrival.

E-flute is our standard, thin enough to print cleanly and stiff enough to protect a tray of chocolate in the mail. B-flute or a double-wall option adds crush strength for heavier boxes or long routes.

The mailer is self-locking, so it assembles without tape, and a tear strip gives a clean first opening. A water-resistant coating helps where coolant packs cause condensation inside.

A die-cut mixed-format insert gives bars, bonbons and truffles their own bays. Pieces that move break at the corners, so each one is seated in its own cavity.

We line every surface that touches chocolate, because cocoa butter marks bare board on contact. The insert board is odour-neutral too, so a spiced truffle won't pass its flavour to the plain bar beside it.

We would keep the box structure the same every month and change what goes around and inside it. A fixed mailer keeps packing simple and gives subscribers a box they recognise on the doorstep.

Monthly variety comes cheaply from a printed sleeve that changes each shipment and a new tasting card with origin and notes. One box specification also lets you order larger runs and hold stock between months.

We print the full interior, which is where subscribers actually look when the lid comes up. Because the same box ships every month, the cost of interior print is spread across a whole year of sends.

Outside, we print CMYK with matte or gloss lamination, or leave the kraft natural. Producer stories and notes about summer pauses usually go on the tasting card, so the box itself stays constant.

Common sizes are 9 × 6 × 2 in and 10 × 8 × 2.5 in, measured on the inside as length by width by depth. Both fit a mixed selection laid out in a single layer.

Size the box for the warm months, when the insulated liner and coolant pack take up room. We'll draw the dieline around your largest monthly selection so every shipment fits.

The minimum is 500 mailers. For a smaller program that can cover several months of shipments from one print run, which also keeps the colour consistent from box to box.

Ahead of Valentine's Day and the holidays, order enough mailers to cover the spike in sign-ups well before the first of those sends goes out.

Production is 7 to 10 business days after artwork approval, and a rush order can be finished in 5 to 7. Samples need 5 to 7 business days, and packing a real month's selection into it is the best test of the insert.

The sample fee is credited to the first mailer production order. For a recurring program, schedule each reorder a month or two ahead of the send date so a busy season never catches you short.