Custom Brownie Boxes
Custom brownie boxes for cut squares and whole slabs, from 100 units. Dividers that keep the squares from fusing, a floor that takes the butter, and a build that goes from the counter to the mail — brownies are one of the few baked goods that survive a courier.
Dense, oily, square and — unusually for a bake — shippable
- Board
- Grease-resistant kraft or SBS, 20–24 pt; E-flute for the mailer
- Grid
- Die-cut paperboard cells cut to your square, 2–3 in
- Counts
- 1, 4, 6, 9, 12, uncut slab
Get a price for Brownie Boxes
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
Cells, so the squares do not become one
Six cut brownies loose in a box arrive as one brownie. A die-cut divider — a grid of paperboard cells, one per square — keeps them apart and keeps the cut edges clean. We cut the grid to your square size: a 2 in brownie and a 2.5 in brownie are different dies, and a grid built for one lets the other slide.
| Single | Sleeve or tuck box, 2.75 × 2.75 × 1.5 in |
|---|---|
| 4 | Two-by-two grid, 6 × 6 × 1.75 in — the gift starter |
| 6 or 9 | Three-by-two or three-by-three, the standard gift and mailer |
| 12 or slab | Four-by-three grid, or an uncut slab in a tray with a sleeve |
The floor, and the butter
A brownie sitting on plain board for an hour leaves a dark patch that shows on the outside. The floor needs a grease barrier, and on a box that ships it needs one that lasts days — a non-fluorinated grease-resistant board rather than a light coating. A greaseproof sheet under the grid is the belt to that pair of braces, and it is what the customer lifts the brownies out with.
Kraft hides the small amount of marking that gets through; white shows it. Most brownie brands choose kraft for that reason and print one color on it.
A box that goes in the mail
Brownies keep, so they ship, and the mailer version is a different construction from the counter box: a heavier board or an E-flute, a self-locking lid with a tuck the courier cannot pop, and a fit tight enough that the grid cannot shift. The box goes in a padded mailer or a corrugated outer, and the size is set against carrier bands for the reasons in our note on box size and shipping cost. A brownie box that is half an inch too tall can cost more to post than to make.
Heat-seal each brownie, or the whole grid, in a film bag before it goes in the box for mail. It keeps the moisture in and the box clean for the week in transit.
Counter box or gift box
- A kraft tuck box with a window shows the tops — the crackle is the selling point.
- A two-piece box with a lift-off lid for a gift of nine, printed inside the lid.
- A rigid box with a fitted grid for a corporate or wedding order, built like our rigid cookie boxes for gifting.
- A slab box — the whole uncut tray with a sleeve — for a bakery that sells brownies by the tray.
Brownie Boxes — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Board
- Grease-resistant kraft or SBS, 20–24 pt; E-flute for the mailer
- Grid
- Die-cut paperboard cells cut to your square, 2–3 in
- Counts
- 1, 4, 6, 9, 12, uncut slab
- Styles
- Windowed tuck box, two-piece gift box, rigid box, self-locking mailer
- Extras
- Greaseproof sheet, film bag for mail, inside-lid print
- Minimum
- 100 boxes
On every job
- Print process
- Flexo in one to six colors, printed on the outer face only and before any lining goes on.
- Color
- Food-safe inks throughout. Kraft mutes color; a white board or liner is needed for anything photographic.
- Tolerance
- Cutting plus or minus 1 mm, and fit confirmed by filling a plain sample from your own kitchen or line.
- Tooling
- A cutting die per size, kept. Molded pulp needs a tool per shape, which is a longer lead and a larger one-off.
- Food contact
- Every board food-contact grade, with grease resistance built into the sheet and never a PFAS treatment.
- Sustainability
- Aqueous linings and unlined boards repulp with ordinary paper. PE-lined cups need cup collection, and we say which you have.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build brownie boxes on
Food packaging is chosen for what the food does to it: grease, steam, heat and time. Every board here is food-contact grade, and none of them uses a PFAS treatment for grease resistance.
Food-grade virgin board
Bleached board made for direct food contact. Clean, bright, no recycled fiber and no mineral-oil risk from recovered paper.
14–24ptGrease-resistant board
Resistance built into the sheet rather than sprayed on. Holds fries, pastry and butter without darkening. PFAS-free.
16–24ptPE-lined cupstock
Board with a polyethylene film for hot and cold liquid. Microwave-safe for reheating; recycled only where cup collection exists.
260–350gsmAqueous-lined cupstock
A water-based lining instead of PE. Repulpable in ordinary paper recycling in more places, and compostable; a slightly shorter hold time.
260–320gsmGreaseproof and glassine
Dense, calendered paper that resists fat through the fiber. Wraps, liners and interleaves; breathable, so pastry stays crisp.
30–55gsmFood-grade corrugated
E and B flute with a food-contact liner, vented where steam has to leave. Pizza, catering and anything hot and heavy.
E and B fluteMolded pulp and bagasse
Fiber pressed into a shape. Holds heat, resists grease with no lining, composts, and takes only an embossed or one-color mark.
Molded to shapeRecycled board
Post-consumer fiber. Used for outers, sleeves and anything that does not touch food directly — not for direct contact.
Non-contact onlyNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
Food finishes are limited by what may touch food, and that is the point.
Food-safe inks
Printed on the outer face only. Every food pack we make uses them, laminated or not.
Uncoated kraft
No coating at all. Breathable, so pastry stays crisp, and it takes one or two colors.
Aqueous varnish
Scuff resistance without a plastic film, so the pack still repulps.
Molded emboss
A logo pressed into pulp or bagasse. No ink, nothing to rub off, and it survives grease.
Grease-resistant face
Not a finish you can see. It is in the sheet, it is PFAS-free, and it is why the print stays clean.
Matte lamination
Available on outers and sleeves that never touch food — a cake box lid, a carrier, a gift sleeve.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing food packaging around a portion, hot: brownie boxes
Food is sized by serving, not by dimensions, and it is served hot, heaped and in a hurry. Send us the portion — or better, the box you use now with the food in it — and we size to how it is actually filled.
- Portion, heaped
- Fries, popcorn and salad are served above the rim. A box sized to a level fill looks mean and spills in a bag.
- Lid clearance
- Enough that a loaded burger or a topped cake does not touch the lid. This is the single most common complaint about a food box.
- Venting
- Hot food steams. Vents in the lid keep pastry and fries crisp; a sealed box is right only for cold food.
- Grease path
- Where the fat sits decides the board. Say if the food is fried, buttered or sauced, and whether it is held for minutes or an hour.
- Stacking in a bag
- Delivery boxes are stacked five high on a bike. The lid has to hold the box above it off the food below.
- Sample fill
- A plain box filled from your kitchen settles the size in one try, and we send one before the run.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Build your Brownie Boxes in 3D
Pick a shape, type a size, choose a board and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about brownie boxes? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
Will the brownies stick together?
Not in a cell grid. Each square has its own paperboard cell, cut to your brownie size, so the cut edges stay clean.
Will grease show on the box?
Not on the grease-resistant grade with a greaseproof sheet under the grid. On plain board it would within the hour.
Can I ship brownies in this box?
Yes, in the mailer build — heavier board or E-flute, a locking lid and a tight grid — inside a corrugated outer. Brownies are one of the few bakes that post well.
What size box for nine brownies?
A three-by-three grid; for 2.5 in squares that is about 8.5 × 8.5 × 1.75 in. Send us your cut size and we confirm.
Do I need to wrap each brownie?
For the counter, no. For mail, a film bag around each or around the grid keeps the moisture in and the box clean over a week in transit.
Is the grease barrier PFAS-free?
Yes. We use non-fluorinated grease-resistant board, and you can say so on the box.
Can I have a window?
Yes, in the lid of the counter box, so the crackle tops show. For the mailer we leave it out; the film would fog and the window weakens the lid.
Can you do a box for a whole uncut slab?
Yes, a tray with a sleeve sized to your baking tray. Bakeries that sell by the slab use it.
Kraft or white?
Kraft — it hides the little marking that gets through and suits the product. White takes full color and shows marks sooner.
What is the minimum order?
100 boxes per count. The box and grid are die-cut and run many-up, so short runs are practical.
How long does production take?
It depends on the board and the quantity. We give a date with the quote rather than a number before we have seen the spec.
Will you send a sample?
An unprinted box and grid in your size, so you can load your brownies and, if it is a mailer, post it to yourself before print.
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