Yoga Mat Packaging Boxes.

A printed band costs a fraction of a full carton and leaves the surface texture exposed to be felt. Mats are bulky, light and cylindrical, so a box is mostly empty space that the freight company charges for. The sleeve carries the print and the carry handle, and the mat itself needs no protection in transit.

Full boxes are reserved for premium and gifting where the print needs to wrap the whole product.

It gets a reinforced handle patch, because the handle is where this pack fails. A mat is carried out of the store, and the load concentrates on a small area of board at the handle cut-out. Extra material there stops the tear-out that an unreinforced handle produces on the first lift.

We do not supply unreinforced handles on this format.

Yes, we cut ventilation perforations so air moves through the pack rather than being trapped in it. Most mats off-gas when new, and a sealed pack concentrates the smell. The perforation lets it dissipate, and a short printed note on the panel explains that the smell is normal and fades.

Airtight sealed packs are something we do not build for mats.

Kraft natural is the most common, since it matches the sustainability positioning most mat brands use. Full CMYK goes on sleeves and boxes for photographic retail artwork, and matte lamination suits natural rubber and higher-tier mats. The spec panel on the front carries thickness in millimetres, material, dimensions and weight, which is how mats are compared on the shelf.

A touch opening or window shows the surface on boxed formats.

The common rolled format is 26 by 5 by 5 inches, sized to the rolled diameter of the mat. Thickness changes the diameter more than length does, so a 6 mm mat and a 3 mm mat need different sleeves even at the same width. We measure from the roll with its strap on, if it ships with one.

Bulk sets the freight cost, so the sleeve is cut to the roll with no slack.

500 units per format and design is where we start. A sleeve and a box are different dielines and are counted separately. Above 1,000 the pricing steps down, and a run can go up to 100,000. Print-only changes across a range of colours are handled as versions on the same sleeve.

Count on 7 to 10 business days from proof approval for the standard run. The rush schedule is 5 to 7 business days. A sample takes 5 to 7 business days, and with a sleeve we recommend one so the handle can be load-tested with a real mat.

The cost of the sample is credited to the production order, and the dieline is free.

Yes, a kraft sleeve is uncoated board and goes into paper recycling as it is. It also uses less material than any box we make for mats, which is why sustainability-led brands prefer it. E-flute boxes recycle the same way. Where a window film is specified on a boxed format we can leave it out and use a touch opening instead, so the whole pack stays one material.