Custom Coffee Boxes.

Three main ones: rigid greyboard gift sets, corrugated subscription mailers and folding boxboard cartons for capsules and multi-packs. Each has a different job. Gift sets are kept, so they get rigid board and a fitted insert. Subscription boxes travel individually through the post, so they get a postal-rated mailer. Capsule cartons need a tray system that makes the count obvious on the shelf.

Because loose coffee bags slump, and a set that arrives leaning looks cheaper than it is. A fitted board insert holds each bag upright in its own cavity and keeps capsules in ordered rows. Tasting notes get a dedicated slot rather than being tucked in loose, where they crumple. The insert is the component that makes a sampler read as a set.

The corrugated outer is lined and an internal bladder carries the coffee, so the board never touches the liquid. The 8 by 8 by 10 inch carrier holds roughly twelve cups, and the handle and base are built to take that weight across a car park. The spout is the one functional risk, so we specify a tap that shuts cleanly rather than one that drips.

Matte lamination is the most requested, with natural kraft board for the speciality register and hot foil for gift and limited releases. Inside print is the highest-value surface on a subscription box because it is what the customer sees on opening. Retail capsule cartons take full CMYK. An origin story panel gives a multi-origin sampler somewhere to put provenance.

Around the bags or capsules going inside, since the insert cavities set the internal dimensions. Tell us the bag format and count, or the capsule type and quantity, and we build outward from there. The 96oz carrier is a fixed 8 by 8 by 10 inches with its spout. Subscription mailers are sized to postal bands as well as to contents.

The order starts at 500 boxes, inserts included. Each box gets cheaper as the order quantity climbs. For a roaster launching a gift set, 500 is usually one season's worth, and the tooling for the insert is reused on every reorder afterwards, so the first run carries the only setup cost.

Standard runs complete in 7 to 10 business days and rush runs in 5 to 7 business days. A sample takes 5 to 7 business days, and we recommend loading it with the actual bags so the insert fit is confirmed before the run. The sample fee is netted off the production order.

Not on its own, since rigid greyboard is built for presentation rather than for postal handling. For subscription and mail order we specify the corrugated mailer with a tear strip closure, which opens without scissors and is rated for individual carriage. A gift set that has to ship goes inside a mailer as an outer.