Lighter Boxes.

The tray travels as a closed carton and opens into a counter display holding 50 lighters upright in rows. Its tuck-tab lid folds back behind the tray and becomes the header card, so the brand sits above the stock while it sells down.

Each lighter gets its own seat, cut to the body, so a customer can lift one out without the rest leaning over. Staff drop fresh units into the empty seats instead of building a new display.

Choose by where the lighter is sold: counter trays for the till, printed blister cards for a peg wall, and hinged rigid cases for gift and premium lines. Plenty of brands run all three at once.

We would keep one artwork system across the family so the tray header, the backer card and the case lid read as the same brand. The tray moves volume, while the card and the case sell the lighter one at a time.

A flocked insert with a single upright seat holds the lighter standing, much like a watch case holds a watch. The hinged lid opens to show the lighter face-on, with the seat set so the front panel, where engraving usually goes, faces the person opening it.

There is room under the insert for a folded warranty or care leaflet. For numbered collector editions we can foil the number on the lid or print it on a card that sits in the lid.

Most counter trays use bright CMYK or Pantone print on gloss or matte laminated SBS board, with spot UV on the logo. Type needs to be larger than you might expect, because a customer looks down at a counter unit from above.

Put the brand name and range on the top flap and header, where the eye lands first. Hot foil, embossing and soft-touch lamination belong mainly on the rigid gift cases, which get handled and seen up close.

A common single lighter box measures about 1.2 × 0.6 × 3.5 in, and trays are laid out to hold 50 of those. We size to the lighter itself, measured at its widest point across the hood and wheel, then add a little clearance so it slides in without scuffing.

Jet and refillable lighters vary a lot in shape, so send us one or two actual units before we cut anything, and the dieline is drawn free of charge.

The minimum for custom lighter packaging is 500 units. Orders scale from there up to 100,000 pieces, so a regional launch and a national rollout come off the same dieline.

For a first run of counter trays, 500 goes a long way, since every tray already carries a trade count of 50 lighters. Singles cards and gift cases can follow once you know which channel is selling.

Production takes 7 to 10 business days once you approve the artwork, and a rush slot brings that to 5 to 7. A physical sample comes first if you want one, and it takes 5 to 7 business days.

We recommend sampling the counter tray in particular, so you can check that every seat grips the lighter and the header stands straight. The sample fee is credited against your production order.

Filled lighters carry fuel, so they usually travel under dangerous goods provisions, and those govern the outer shipping carton more than the retail pack. Your carrier or freight forwarder sets the exact marks and packing instructions.

Our part is to build the retail trays and cases to fit snugly inside those outers and leave clear panel space for any handling text, child-safety wording or age print your market asks for. The board itself can be odour-neutral SBS or recyclable kraft.