Some products need a box that slides open like a drawer instead of lifting off. Choosing tray and sleeve packaging gives you a shallow base paired with a printed outer cover, and the reveal feels deliberate. This guide explains how it works, which materials suit it and what affects the price.
How the Structure Works
A tray holds the product, and a sleeve slides over it to close the box. The sleeve is usually printed, while the tray can be plain, lined or printed inside.
Pulling the tray out creates a neat reveal, which is why the format suits gifts and premium goods. Since the sleeve carries most of the branding, you can refresh the design later without changing the tray.
Products That Suit This Format
Four product groups use it most often:
- Candles and home fragrance, where the tray stops jars shifting.
- Cosmetics and skincare sets that need an inner insert.
- Electronics and accessories that benefit from a snug fit.
- Chocolates and food gifts, provided the tray is lined for direct contact.
Heavy or very fragile items are better suited to a rigid box or a corrugated mailer.
Board Choices and Strength
Sleeves are normally made from folding carton board of around 300 to 400 GSM. That weight prints well and holds its shape without feeling stiff.
Trays need more strength. Thicker paperboard works for light items, while E flute corrugated board suits heavier contents. Luxury brands sometimes choose a rigid greyboard tray wrapped in printed paper, though it costs more and takes up more storage space.
For anything touching food, ask your supplier for board suitable for direct contact and confirm it meets UK food contact rules.
At Boxo Packaging, we usually ask for product weight, dimensions and sales channel before recommending a board grade, because a shelf item and a posted item need different strength. This matters most with tray and sleeve packaging, where a loose fit shows straight away.
What Drives the Price
Order quantity has the biggest effect, since setup and tooling are spread across more units. Board grade, size, print colours and finishing then add to the total.
Two components mean a higher unit price than a single piece carton. A new cutting die is a one off charge, so reordering an existing design costs less. Ask for quotes at two or three quantities to see where the price drops.
Finishes and Sustainability
Matt lamination, spot UV, foil and embossing give the sleeve a premium feel, though each adds cost and some make recycling harder. A simple one or two colour print on kraft board is often cheaper and easier to recycle.
Look for FSC certified board, water based inks and designs that use a single material. Avoid claiming a box is “fully green”, as every material has some footprint.
Ordering Tips Before You Commit
Request a physical sample and test it with the real product. The sleeve should slide on with light resistance, neither falling off nor tearing the tray when removed.
Check the dieline proof carefully and allow extra lead time, since production and freight can take several weeks. A good supplier will question your specification rather than simply accept it. That is how we work at Boxo Packaging, because a small fix at the design stage costs far less than a reprint, particularly with tray and sleeve packaging.
Custom Boxes: A Practical Guide for Brands of Every Size
Many brands only think about their boxes once a product is ready to ship. By then, decisions about size, strength and finish can feel rushed. Planning custom boxes early helps you protect your goods, control costs and make a better first impression. This guide covers the main styles, materials and cost factors so you can brief a supplier clearly.
What Makes a Box Custom
A custom box is sized, printed or structured around a specific product instead of being picked from a standard catalog. A snug fit limits movement in transit, which is the main cause of scuffs and breakage. It also reduces the need for void fill and leaves room for inserts or a thank you card.
Standard sizes are usually cheaper at low volumes. Tailored sizing tends to pay off once you reorder regularly and your dimensions are stable.
Popular Styles and Their Uses
The right style depends on product weight, fragility and sales channel. Four options cover most requests:
- Mailer boxes: self locking corrugated boxes that suit ecommerce orders.
- Folding cartons: lightweight, flat packed boxes for cosmetics, supplements and dry food.
- Rigid boxes: thick, wrapped boxes for gifts and premium goods, though they take more storage space.
- Shipping cartons: plain corrugated boxes for heavier parcels.
Start with the style that suits your bestseller, then adapt it across your range.
Materials and Board Weights
Folding cartons usually use board of 300 to 400 GSM, either white SBS for sharp color or kraft for a natural look. Corrugated boxes use E flute for rigidity or B flute for cushioning, with double wall board for heavy or fragile loads.
For anything touching food, ask your supplier for board suitable for direct contact and confirm it meets FDA food contact requirements.
At Boxo Packaging, we usually ask for product weight, dimensions and shipping route before suggesting a board grade, because these details decide strength far more than appearance does.
Printing and Finishing Options
Digital printing suits short runs and frequent design changes. Offset printing gives richer color and a lower unit price on larger orders, and flexographic printing is common directly on corrugated board.
Matt lamination, spot UV, foil and embossing add a premium feel, though each raises the cost. A simple one or two color design on kraft board often looks smart and stays affordable.
Cost Factors and Sustainability
Order quantity has the biggest effect on price, since setup and tooling are spread across more units. Board grade, size, print colors and finishing then add to the total, and a new cutting die is a one off charge.
Look for FSC certified board, water based inks and single material designs that recycle more easily. Avoid claiming a box is “fully green”, as every material has some footprint. Plastic windows and heavy lamination can complicate recycling.
Ordering Tips Before You Commit
Request a physical sample and fill it with real stock before approving a full run. Check the dieline proof, test the closure and drop a packed box from a realistic height.
Allow extra lead time, since production and freight can take several weeks. A reliable supplier will question your specification rather than simply accept it. That is how we work at Boxo Packaging, because fixing a problem early costs far less than a reprint.