Custom Sunscreen Boxes & Sunscreen Packaging
Sunscreen is regulated as an over the counter drug, which means the carton has rules that most beauty products never deal with. Get the panel wrong and you cannot sell it. That is the first thing we tell every client who comes to us for sunscreen packaging at ZEE Packaging, before we talk about print or finish at all.
The Panel Rules Come First
Every sunscreen box has mandatory content and a fixed structure. We lay it out on the dieline before anything else.
- SPF number on the front, large and unmissable
- Broad spectrum claim if it applies
- Water resistance, 40 minute or 80 minute, stated plainly
- Drug Facts panel with Active Ingredient, Uses, Warnings, Directions
- Inactive ingredient list
- Net weight in oz and ml
- Lot code and expiry space, leave it blank for inkjet
- Barcode with proper quiet zone
The Drug Facts block takes up real estate, so we plan panel space early. Squeezing it in later is where sunscreen packaging projects go wrong.
- Straight tuck end carton the standard sunscreen box for tubes and bottles
- Reverse tuck end cheaper, fine for volume sunscreen packaging
- Seal end carton glued, better tamper resistance
- Tall slim carton for sticks and roll on sunscreen boxes
- Multipack shipper corrugated, for club stores and bundles
- Travel size carton small format for 1oz and 1.7oz
Sizes We Run Often
Every sunscreen box is built to your container, though these come up over and over:
- 1.5" x 1" x 4.5" for a 1oz travel tube
- 1.75" x 1.25" x 5.5" for 3oz tube, our most common sunscreen box
- 2" x 1.5" x 6" for 6oz and 8oz tubes
- 2.25" x 2.25" x 6.5" for pump bottle
- 1.5" x 1.5" x 4" for stick sunscreen packaging
- 6" x 4" x 6" for a multipack
Send the tube dimensions with cap on, including the shoulder, and we build the dieline from there.
Board And Durability
Sunscreen lives in beach bags, glove boxes and bathroom shelves. The sunscreen box needs to survive all three.
- SBS C1S 18pt to 22pt for most printed sunscreen packaging
- 24pt on larger pump bottle cartons
- Kraft board for mineral and reef safe ranges
- Corrugated E flute for multipack shippers
- Metallized board for premium SPF lines
We do not go under 16pt here. A greasy hand and a humid bathroom will wreck a thin uncoated carton fast.
Finishes That Handle Moisture
- Matte or gloss lamination, the film is doing real work in this category
- Aqueous coating as a lower cost alternative
- Soft touch for premium sunscreen boxes, though they mark easier
- Spot UV over the SPF number
- Foil stamping, gold and silver suit sun care
- Emboss on kraft for mineral ranges
Uncoated stock looks lovely in a proof but it stains the second sunscreen touches it. We steer clients toward laminated film on any sunscreen box that goes near a beach.
Greener Options
- Recycled kraft sunscreen boxes
- FSC certified board, certificate on request
- Soy based inks
- Reef safe and mineral claim areas on panels
- Right sized sunscreen packaging so you ship less air
How We Work
- 100 unit minimum on any sunscreen 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
Do you write the Drug Facts panel for us?
No, we print what you supply. Your regulatory person or formulator provides the final wording and we lay it out to the required format on the sunscreen packaging.
How small can the Drug Facts text go?
There is a minimum set by regulation and it is larger than most brands expect. Send us your copy early so we can check the panel fit before you commit to a carton size.
Will the carton hold up in a beach bag?
Laminated film, yes. Uncoated board, no. Sand and lotion together destroy an unlaminated sunscreen box quickly.
How much is a box of sunscreen?
Rough estimate is $0.28 to $0.85 per unit for folding cartons, $0.90 to $2.20 for corrugated multipacks at moderate quantity. Foil and spot UV push it higher. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
Where does the lot code go?
We leave a clear coding window on the end flap or base panel, usually uncoated so your inkjet adheres properly.
Can you do a multipack for club stores?
Yes, corrugated shippers with dividers so each tube sits separate and nothing rubs during transit.
Does soft touch work for sun care?
It looks great but it shows grease marks faster than matte film. For a premium indoor range it is fine, for beach products we lean matte.
