Custom Flip Top Cigarette Boxes & Hinge Lid Cigarette Packaging
The flip top is one of the most engineered pieces of paperboard packaging there is. It has to open thousands of times without the hinge tearing, hold its shape in a pocket, and still cost pennies at volume. We produce this style regularly at ZEE Packaging and there is more going on in a flip top cigarette box than most people realize.
How The Structure Actually Works
A hinge lid cigarette box is three parts working together, and if any one is off the whole thing feels wrong.
- Outer shell the body, usually one piece of board scored to fold around the inner
- Inner frame the collar that the lid closes against, this is what creates the click
- Lid hinged at the back, sits over the collar
The collar height is the detail people get wrong most often. Too tall and the lid wont sit flush, too short and the flip top cigarette box feels loose and cheap in the hand.
Sizes We Run
Every hinge lid cigarette box is built to your product, but these are the formats that come up:
- King size, roughly 3.4" x 2.2" x 0.85" for 20 sticks
- 100s, roughly 3.9" x 2.2" x 0.85"
- Slim, roughly 3.4" x 2" x 0.7"
- Super slim, narrower again with a tighter collar
- 10 stick pocket format, a shorter flip top cigarette box
- Custom dimensions for herbal, pre roll and non tobacco products
Send us the stick count, circumference and length and we build the dieline from there.
Board Selection
- 18pt to 22pt cardstock is the working range for most flip top cigarette box work
- 24pt when you want a more solid, premium feel in the hand
- SBS C1S for clean printed surface
- SBS C2S when you print the inside of the lid as well
- Kraft board for natural and herbal ranges
- Metallized board for high end hinge lid cigarette boxes
Under 16pt the hinge starts failing early. We would rather put you a grade up than have lids tearing after a week.
Print And Finish
- Offset for volume, digital for smaller runs
- CMYK plus spot Pantone for exact brand color
- Matte or gloss lamination
- Soft touch on premium hinge lid cigarette boxes
- Hot foil stamping, gold and silver both very common here
- Emboss or deboss on the front panel
- Spot UV over the logo for contrast
Inside lid printing is worth mentioning. It is cheap, it gets seen every single time the pack opens, and hardly anyone uses it well.
Regulatory Panel Planning
This category carries more mandatory copy than almost any other, and the rules differ by market.
- Health warning area, size and position vary by jurisdiction
- Plain packaging rules apply in some markets entirely
- Tax stamp placement, leave clear space for it
- Batch code and manufacture date area
- Barcode with proper quiet zone
We lay all of it on the dieline before press so nothing gets trimmed or covered. You supply the compliance wording, we handle placement.
Inner Components
- Inner frame or collar, always
- Foil or metallized inner liner
- Tear tape and overwrap
- Printed inner lid message
Greener Options
- Recycled kraft flip top cigarette box with no lamination
- FSC certified board, certificate on request
- Soy based inks
- Paper inner liner instead of foil laminate
How We Work
- 100 unit minimum on any flip top cigarette box design
- Free 3D mockup and flat proof
- Free dieline from our inhouse team
- 5 to 8 business day urgent turnaround
- Free shipping worldwide
Frequently Asked Questions
What does a flip top cigarette box cost?
Rough estimate is $0.18 to $0.60 per unit at moderate quantities depending on board, print coverage and finishing. Foil and soft touch push it higher. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
Why does my lid not close flush?
Nine times out of ten it is collar height. We adjust the inner frame on the dieline and it usually solves straight away.
How many openings will the hinge take?
On 18pt or above with a proper score, several thousand. Thin board and a shallow crease are what cause early tearing.
Can you print the inside of the lid?
Yes and we always suggest it. That surface gets looked at more than the front panel over the life of a pack.
Do you supply the inner foil liner?
We do, foil laminate or a paper alternative if you want the recyclable route.
Can you make it for non tobacco products?
Absolutely. We run this format for herbal blends, pre rolls and various pocket products regularly.
Who is responsible for the health warning wording?
You are. We place and size it exactly as you supply, but the compliance copy has to come from your side.
