Custom 100ml Bottle Boxes & 100ml Bottle Packaging
So let us talk about 100ml, because this is one of the busiest size we print here at ZEE Packaging. It is the standard perfume and eau de parfum volume, also it covers a lot of serum, toner and hair oil, and on top of that it sits right on the airline liquid limit which makes it a travel favorite also. All of this demand means one thing only, that the 100ml bottle box has to work much harder than a normal carton. We print these almost daily, so whatever we have learned over the time, we are sharing it here.
Glass Is The Whole Problem
Honestly speaking, the glass itself is where all the trouble starts. Almost every 100ml bottle is glass, and glass is very unforgiving once it goes inside a carton.
- Too loose and it rattles, then the cap chips against the board
- Too tight and the flap wont close, or the score line cracks
- A heavy base bows the bottom panel if the board is thin
- Atomizers and pumps add height, which people forget to measure
So kindly measure the bottle with cap on, at the widest point, and give us that number only. We build the 100ml bottle packaging from real figures, never from a spec sheet estimate.
Sizes We Print Most
Every 100ml bottle box is made as per your product, but these sizes come up again and again:
- 2" x 2" x 5" for a slim cylindrical bottle
- 2.5" x 2.5" x 5.5" for a standard square perfume 100ml bottle box
- 3" x 1.5" x 5" for a flat rectangular flacon
- 2.75" x 2.75" x 6" for tall bottles having a large cap
- 5" x 3" x 5.5" for a two piece gift set
- 6" x 4" x 6" for mailer style 100ml bottle packaging
In case if you are unsure, just send the bottle over. We size it here itself and it saves you one full round of proofing.
Board Weight
Now coming to the board, this is the part where most of the decision happens:
- 18pt to 20pt is our minimum for a glass 100ml bottle box
- 24pt for heavier flacons and thick base glass
- SBS C1S for smooth printed retail 100ml bottle packaging
- Rigid greyboard 36pt or 48pt for premium fragrance
- Kraft board for natural skincare and apothecary ranges
- Corrugated E flute when the box is shipping on its own
Many clients ask us about 14pt to save some cost, and most of the time we talk them out of it. A 100ml glass bottle in thin board, it just looks sad by the time it reaches the shelf.
Styles That Suit The Category
Regarding the style, these are the ones working best over here:
- Reverse or straight tuck end, this is the everyday retail format
- Seal end carton for tamper evidence
- Rigid lid and base for premium fragrance 100ml bottle packaging
- Drawer slide, which is quite popular for gifting purpose
- Window carton so that the juice color shows through
- Corrugated mailer for direct to customer orders
Finishing That Sells Fragrance
No doubt, finishing is where this whole category gets decided.
- Soft touch lamination, this is the most asked for finish in fragrance
- Foil stamping, gold and silver, almost it is expected on perfume
- Emboss or deboss on the logo panel
- Spot UV over a matte base, for that contrast
- Metallic and pearlescent board
- Printed inner panel, it is cheap and still it gets noticed
What The Panel Has To Carry
Then comes the legal side, and the panel it has to carry all of this without fail:
- Net contents in ml and fl oz
- Full ingredient list, INCI order
- Batch code and PAO symbol, kindly leave clear space for coding
- Flammability warning for alcohol based fragrance
- Manufacturer address and country of origin
- Barcode with proper quiet zone
Our prepress team checks each one of these against the dieline before press, so that nothing gets trimmed off at the end.
Greener Options
Also nowadays many brands ask about the greener side, so we have these options:
- Recycled kraft 100ml bottle box with no film
- FSC certified board, certificate on request
- Soy based ink
- Paperboard insert instead of foam or plastic
- Right sized 100ml bottle packaging, so that you ship less air
How We Work
- 100 unit minimum on any 100ml bottle box design
- Free 3D mockup and flat proof
- Free dieline from our own designer
- 5 to 8 business day urgent turnaround
- Free shipping worldwide
Frequently Asked Questions
How much do you charge to manufacture a box for a 100ml bottle?
Rough estimate is $0.35 to $1.00 per unit for folding cartons, $0.95 to $2.40 for mailers and $2.30 to $5.80 for rigid at moderate quantity. Foil and window patching push it higher. Shipping is already included in our price. This is estimate only, so ask our team for a exact quote.
Do we need an insert for glass?
For anything which ships alone, yes. A die cut paperboard insert stops the movement and it costs very little if you compare it with one broken bottle.
Can you fit an atomizer and a travel spray in one box?
Yes, we build a divided insert so each piece sits in its own well and nothing is knocking together.
Will a window weaken the carton?
Slightly it does, so we place it away from the score lines and patch the same with clear PET. On a 100ml bottle box it usually holds fine.
How small can the ingredient text go?
6pt is our floor. Below that the INCI list starts to break up on press, especially on uncoated stock.
Can you match a metallic gold exactly?
For gold, foil matches much better as compared to metallic ink. Just give us the foil reference or one physical sample and our team matches it.
Do you print inside the lid on rigid?
We do, and for fragrance it is worth it. This is the first thing somebody sees the moment the box opens.
