Custom Churro Boxes
Custom churro boxes from 100 — open scoop cups, cups with a holder for a chocolate or dulce de leche dip, and trays for a churro board — in grease-resistant board that takes hot oil and loose sugar without going see-through.
A churro is long, hot, sugared and eaten standing up
- Board
- Grease-resistant food board, 14–18 pt, non-fluorinated barrier on the food side; kraft or white
- Builds
- Open scoop cup, scoop cup with dip-pot holder, lidded buffet tray, vented carry box
- Dip holders
- Die-cut collar, side pocket or tray well, sized to your dip pot
Order online
Order churro boxes
Starting from $1.20 per unit
Printed to your artwork or plain, sold in runs of 100 up to 5,000 units per product online. Freight to the US, UK, Canada and Australia is inside the price.
How an online order runs
- Add the units you needThen check out with your delivery address. Add other products to the same order on the way.
- A digital proof comes backLaid on the dieline, before anything prints. Change it as often as you need.
- Pay once you approve itPay by PayPal invoice or bank transfer after you approve your digital proof, or cash on delivery in the US and Canada.
- We make it and ship it deliveredYour delivery date is confirmed with the proof, against the spec and your fill date. Freight and customs are handled on the way to you.
Another size, board or finish, or more than 5,000 units? Send the spec for a price instead. Freight by market and our terms cover delivery and remakes.
Get a price for Churro 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.
Three shapes a churro stand actually uses
| Open scoop cup | Tall front, cut-down back, like a fries scoop; holds 4–8 sticks upright for walking |
|---|---|
| Cup with dip-pot holder | A scoop cup with a die-cut collar or side pocket that grips a 2 oz dip pot |
| Buffet or sharing tray | Lidded tray box with a well for two or three dips; churro boards and catering |
| Closed carry box | Tuck-top box with vents for a dozen to take home; keeps sugar off a car seat |
Hot oil and a sugar coating on the same board
A churro goes into the cup a minute out of the fryer, and the oil on its ridges will soak into plain paperboard and show through the print within a couple of minutes. We build churro cups from a grease-resistant food board, uncoated on the outside so the print stays matte, with a non-fluorinated barrier on the food side. The barrier choices are the same ones set out in our guide to grease barriers without PFAS.
Sugar is the other half of the job. Loose cinnamon sugar collects in the bottom of a cup and spills when the cup is tipped to reach the last stick, so the scoop shape keeps a solid, unslotted base and a back panel tall enough to stop the sugar running out of the open side.
Where the chocolate goes
- A die-cut collar at the top of the cup grips a round dip pot so it does not ride down into the sticks.
- A side pocket folded into the cup wall holds the pot beside the churros on a cup that has to stay narrow.
- A tray well, pressed or glued in, sized to the pot you already buy, measured from the pot not from a catalog.
- For a sharing tray, two or three wells along one end so several people can dip without passing the pot around.
Sizing to the stick, not the portion
Churros vary more than people expect. A Spanish churro is thin and looped or cut short; a street-market churro can be a foot long and straight; filled churros are thicker and shorter. We size the cup height to the length you cut so a third of each stick stands above the rim to be picked up, and the cup mouth to the number you sell in one portion. Send a portion as you serve it and the dip pot you use, and the dieline comes back drawn around both.
Cut lengths change between a stand and a sit-down shop, so a brand that sells both often needs two cup heights from one design rather than one cup that suits neither.
Print for a stand that is seen from across a market
Churro cups are carried through crowds, and that is most of their value as a piece of print. Bold color on the tall front panel, the stand name large enough to read at a few yards, and the back left plain or carrying a short line and a handle. Flexo or offset print on the outside, food-safe inks, nothing printed on the side that touches the churro. The same open-top shapes run through our custom food boxes for fries and snacks.
If the cup will sit in a holder on the counter before it is filled, tell us the holder size; the base has to drop into it.
Packing churros for delivery apps
Delivery is hard on a churro. Twenty minutes in a closed bag turns a crisp stick soft, and a cup tipped on its side in a courier bag empties sugar everywhere. For delivery we use the vented carry box rather than the open cup: the churros lie flat on a liner, the lid vents release steam, and the dip pot sits in its own well with the lid on. A tamper sticker across the tuck shows the order has not been opened on the way.
Churro 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 food board, 14–18 pt, non-fluorinated barrier on the food side; kraft or white
- Builds
- Open scoop cup, scoop cup with dip-pot holder, lidded buffet tray, vented carry box
- Dip holders
- Die-cut collar, side pocket or tray well, sized to your dip pot
- Sizing
- From the churro cut length and the number per portion
- Full color outside, food-safe inks, unprinted food contact side
- Minimum
- 100 churro boxes per size
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 churro 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: churro 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.
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Build your Churro 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 churro 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.
How tall should a churro cup be?
Tall enough that about a third of each churro stands above the rim. We take the height from the length you cut, so a short Spanish churro and a foot-long market churro get different cups.
Can a churro box hold the chocolate dip as well?
Yes. A die-cut collar or a side pocket on the cup grips a dip pot, and a buffet tray gets wells for two or three pots.
Will churro oil soak through the box?
Not with the grease-resistant board we use. The barrier is on the food side, so the print on the outside stays clean.
Do churro boxes use PFAS grease coatings?
No. The grease resistance comes from a non-fluorinated barrier board or coating.
How do you stop cinnamon sugar spilling from a churro cup?
The scoop keeps a solid base and a tall back panel, so loose sugar collects in the cup instead of running out of the open side.
Can you size the dip holder on a churro cup to our pots?
Yes. Send the pot you buy and the collar or well is cut to it, rather than to a standard size.
What box works for a dozen churros to take home?
A vented tuck-top carry box. The vents let steam out so the churros keep their crunch on the way home.
Do you make churro boards or sharing trays for catering?
Yes. A lidded tray box with dip wells along one end holds a sharing portion and stacks for delivery.
Can filled churros go in the same churro boxes?
Filled churros are shorter and thicker, so they usually need a wider, lower cup or a tray with a divider.
Are churro cups printed on the inside?
No. The food contact side stays unprinted; all the print is on the outside panels.
What is the minimum order for churro boxes?
One hundred per size. A stand that needs two cup heights orders each height at that minimum.
Same range
