Lotion Boxes.

Because a full 250ml bottle weighs close to 300 grams, and a tucked bottom under that load eventually lets go. It usually fails in a warehouse stack rather than on a shelf. A crash-lock base spreads the weight across the whole panel instead of one flap, and it locks as the carton is squared up on the packing line.

We specify the carton to stack six high in distribution.

About 1.5mm in total, because a waxy HDPE bottle slides if the carton is loose. Too much room and the bottle rattles on the inside of the carton, and too little slows the packing line. Height is the bottle plus the cap plus a few millimetres, measured with a pump head in its shipping position.

Send a filled bottle and we'll cut a blank to check the fit.

20pt SBS for heavier fills, or 18pt kraft where the range is natural and the bottle is lighter. The extra caliper on SBS keeps a full bottle from bowing the side panel. Kraft is common in body care for cost and for a plain, unbleached look. FBB trims board cost on a carton this size without losing stiffness.

Large multipacks move to E-flute corrugated, since a folding carton alone will not survive distribution at that weight.

Matte lamination is the body-care default, and aqueous coating is the choice where a recyclability claim applies. Soft-touch works on a carton this size because there is a lot of surface to feel, and it suggests the texture of the product inside. A deboss reads as restraint, which suits the category better than foil. Spot gloss over a botanical illustration is the usual accent.

High gloss is for mass fixtures where visual impact matters more than hand feel.

About 2.4 by 2.4 by 6.5 inches inside for 250ml with a pump or disc cap, and 2.0 by 2.0 by 5.5 inches for 150ml. A carton at 250ml gives more than 60 square inches of panel, so the ingredient list sits at a comfortable size. Front panel takes the brand and the claim, back takes the list and directions, sides take range navigation.

Every bottle mould is different, so the carton is cut from yours.

500 per size and print version. A 150ml and a 250ml carton are separate dielines and each needs its own 500, even with identical artwork. The upper limit is 100,000 per order.

Kraft and PCW recycled board are both available at the minimum quantity.

7 to 10 business days once the proof is approved, with a rush option at 5 to 7 business days. An auto-bottom carton is glued as well as cut, and that step is already inside the window. Samples take 5 to 7 business days and a glued sample is the way to confirm the crash-lock base holds a full bottle.

The sample fee is offset against the bulk order, and delivery is anywhere in the USA.

Yes, and body care is the easiest cosmetic category to keep single-material. Colour accuracy matters less here, so PCW recycled board works without the swatch problems a colour range has. Aqueous coating instead of a film lamination keeps the carton repulpable, and water-based inks are standard.

Kraft board with one ink and no coating is the plainest recyclable spec and reads as honest on a natural range.