Custom Packaging Designed For Bottles Industry

Custom Bottle Boxes & Bottle Packaging

Small bottles are honestly some of the trickiest things we print. Glass is heavy, dropper caps add height nobody accounts for, and a pump reaches further than people think. We have built a lot of custom bottle packaging at ZEE Packaging and most of the problems we see start with a measurement somebody guessed.

Measure The Bottle, Then Talk To Us

The bottle decides the bottle box, not the other way round. Cap on, pump up, everything included.

Our most requested bottle box sizes:

• 1.25" x 1.25" x 3.5" for 1oz dropper, the smallest bottle packaging box we run often
• 1.5" x 1.5" x 4" for 2oz serum and oil
• 2" x 2" x 5.5" for 4oz pump, a very common bottle box
• 2.5" x 2.5" x 7" for 8oz lotion and toner
• 3" x 3" x 8" for 12oz and 16oz, a tall bottle box for body products
• 5" x 3" x 4" for a two bottle set, bottle packaging for gifts or duos
• 8" x 6" x 4" for a full kit, multi bottle packaging with insert

If you dont have the numbers, mail us a bottle. We measure it here and build the dieline around it, no charge.

Which Style Fits

• Reverse tuck end our cheapest bottle packaging box, fine for most retail shelves
• Straight tuck end flaps tuck backward so the front face stays clean
• Seal end carton glue sealed, use it when you want tamper evident bottle packaging
• Mailer box for direct to door bottle box shipment with tissue and insert
• Rigid box heavy lid and base, this is luxury bottle packaging territory
• Window carton a die cut opening so shoppers see the liquid inside the bottle box
• Sleeve slim outer for bottle packaging boxes you already print, good for seasonal variant

Board Weight Matters More Here

Glass is heavy and thin board bows under it. What we recommend for a bottle box:

• 18pt to 24pt SBS for most glass bottle packaging
• 14pt to 16pt if it is a plastic or PET bottle box
• Natural kraft for botanical and organic bottle packaging box look
• Corrugated E flute when the bottle box ships on it own with no outer carton
• Rigid greyboard 36pt or 48pt for premium gift bottle packaging

We have seen 12pt bottle packaging boxes crush in transit more times than we can count. It saves a few cents and costs you a return.

Keeping The Glass Still

A rattling bottle box feels cheap and breaks stuff. Options we build:

• Die cut paperboard insert, cheapest and fully recyclable
• Corrugated partition for multi bottle packaging
• Foam insert when the bottle is expensive
• Snug internal dimensions, sometimes the bottle box just needs to be sized right

Finishing That Actually Sells

Most of the perceived value in bottle packaging comes from surface, not structure.

• Soft touch lamination, the single biggest upgrade for a bottle box
• Matte or gloss film
• Gold, silver, rose gold or holographic foil on your logo
• Emboss and deboss, look great on kraft bottle packaging boxes
• Spot UV over matte for contrast
• Metallic and pearlescent stock

A matte bottle box with one clean foil mark beats a busy full color print in most categories we work in.

The Copy On Pack

Cosmetic and supplement bottle boxes carry a lot of mandatory text:

• INCI ingredient list
• Net content in fl oz and ml
• Batch and expiry space, leave it blank for inkjet coding
• Business name, address and country of origin
• Barcode with quiet zone
• Warnings and PAO symbols where they apply

Our prepress team checks every panel against the dieline so nothing gets trimmed off your bottle packaging.

Eco Options

• Recycled kraft bottle boxes, no film
• FSC certified board with certificate
• Soy and water based inks
• Paperboard inserts instead of foam
• Right sized bottle packaging so you ship less air

Working With Us

• 100 unit minimum on any bottle box design
• Free 3D mockup and flat proof
• Free dieline and artwork help
• 5 to 8 business day on urgent
• Free shipping worldwide

Frequently Asked Questions

Can you do a window on a bottle box?
Yes, patched with clear PET film. Boxes with windows need a bit more care on the die but they come out nice.

Do you supply the bottle label too?
We do. Plenty of clients order labels and bottle packaging together so the color matches across both.

How much do bottle packaging boxes cost?
Estimated cost is $0.35 to $0.95 per unit for folding cartons, $0.90 to $4.30 for mailer boxes and $2.00 to $8.20 for rigid boxes at moderate quantities. Shipping included in our price. This is estimate only so get a quote for a exact figure.

How thin can I go on board?
For glass, dont drop below 16pt. It bows at the base and the whole bottle box looks sad on shelf.

Can you print inside the box?
Yes and it works well for ingredient story or a short brand note on the inner flap.

What files do you need?
AI, PDF, EPS or PSD, 300 DPI, CMYK or Pantone, fonts outlined, 1/8" bleed.

Can we run a small test batch?
That is what the 100 unit minimum is for. Test the bottle box, see how it performs, then scale.