Protein Bar Boxes.

A perforated line across the front panel lets the whole face tear away by hand, so the case goes from shipper to display without unpacking. The bars stay in the tray and the printed panel that remains becomes the facing. Cutting the perforation so it tears cleanly but survives the pallet is the part that takes tuning.

The multi-pack version has no tear line and is built as a plain tuck-end carton for the shelf.

Bars slide forward on an angled base insert, so the display keeps a full facing as it empties. A flat base leaves the last few bars lying jumbled at the back of a tray that looks sold out from the aisle. We build the angle into the insert rather than the outer box, which keeps the case square for stacking.

We do not build flat-based display versions for this reason.

No, because each bar is already sealed in its own film wrapper. The carton's job is grouping and shelf presence, so the board can be chosen for print and stiffness rather than moisture or grease resistance. That also makes high recycled content practical, since the bars never touch the board.

We do not offer barrier linings on this format, and you do not need them.

Grams of protein goes on as the dominant element, with sugar, calories and protein source in a second tier. That is the order shoppers compare in, so the print hierarchy follows it and the brand takes the space that is left. Full CMYK on folding boxboard is the standard for multi-packs, litho-laminated board for displays that need photographic quality on corrugated.

Across a range we set up flavour coding so each variant reads from a distance.

A twelve-count carton runs around 8 by 5 by 2 inches, holding bars of roughly 4.5 by 1.75 by 0.75 inches. Twelve is the step the trade works in, so the multipack is sized to that count and to the shelf fixture it sits on. We measure from your wrapped bar, since the film seal adds to the length.

We start at 500 cartons for a single size and design. Above 1,000 the unit price moves down in tiers, and the same run can scale as far as 100,000. If you are ordering both a multipack and a display version, each counts as its own minimum because they cut from different dielines.

Allow 7 to 10 business days for production from the approved proof. If launch dates are tight we can pull that in to 5 to 7 business days at a rush rate. Samples take 5 to 7 business days and are the right time to test the tear-away perforation with a real case of bars.

Whatever the sample costs is credited back when you place the production run.

Yes, and this is one of the few food cartons where high post-consumer content is easy to justify. The bars are film-wrapped, so recycled fibre never contacts them and there is no barrier requirement to work around. Kraft board suits whole-food and minimal-ingredient positioning, and a visible recycled-content mark can be printed for brands that lead on sustainability.

Plain boxboard and E-flute both go into the normal paper recycling stream.