Custom Ecommerce Coffee Boxes
Custom ecommerce coffee boxes sized to your bag — one, two or four — as a letterbox mailer, a subscription box or a shipper, printed inside and out, from 100. Dieline and price the same working day.
The bag is the product; the box is the delivery
- Board
- E flute kraft or white-lined; B flute for shippers
- Builds
- Letterbox mailer, self-locking mailer, shipper, subscription box with insert
- Sizing
- Bag plus 5 mm; letterbox format under the postal thickness limit
Get a price for Ecommerce Coffee 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.
Sized to the bag, and the postage band
The letterbox format is the one that changes the economics: a box under the postal thickness limit goes as a large letter and needs no one at home. It only works if the bag is flat enough, which is a conversation about the bag as much as the box.
Pods and sachets sold beside the beans go in a carton that tears open into a dispenser.
| 250 g bag, single | Letterbox mailer, about 230 × 150 × 40 mm; through most slots |
|---|---|
| 250 g × 2 | Mailer, about 230 × 160 × 80 mm; a small parcel |
| 500 g or 1 kg | Mailer or shipper sized to the bag; a parcel |
| Subscription with extras | Box with an insert for the bag, a card and a sample |
Mailer, shipper or subscription box
Our mailer boxes for every product cover the construction in detail; this page is about the coffee-specific decisions.
- E-flute mailer with a self-locking lid — no tape, prints well, the standard for one or two bags.
- B-flute shipper for a kilo or a multi-bag order; tape-sealed; plain or one color.
- Subscription box — a mailer with an insert, a printed inside and room for a card and a sample.
Protecting a bag with a valve
A coffee bag has a one-way valve and a soft body. Pressed hard in transit the valve can vent and the bag flattens; crushed at a corner the seal can split. A box cut close to the bag with 5 mm of clearance holds it still, and E flute takes the knocks. Void fill is unnecessary in a box sized right, and customers dislike it.
Send the bag filled, not empty. A filled 250 g bag is a different shape from the flat pouch it started as.
Print inside and out
A coffee mailer is opened at a kitchen table and often photographed. The outside is the brand in one or two colors on kraft, or full color on a white liner; the inside is where the effort goes — a pattern, a tasting note, a message. Inside print is a second pass and costs little on a run of a few hundred.
Subscriptions, and the box that changes monthly
A subscription roaster changes the coffee, not the box. One mailer die, a printed insert card that changes each month, and a reorder of the same box every quarter. The die is kept, the print stays constant, and the monthly variation is a card.
Ecommerce Coffee 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
- E flute kraft or white-lined; B flute for shippers
- Builds
- Letterbox mailer, self-locking mailer, shipper, subscription box with insert
- Sizing
- Bag plus 5 mm; letterbox format under the postal thickness limit
- 1–2 colors on kraft or full color on white; inside print
- Insert
- Board insert for bag, card and sample
- Supply
- Flat; mailers fold without tape
- 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 ecommerce coffee 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: ecommerce coffee 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 Ecommerce Coffee 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 ecommerce coffee 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.
Can a 250 g bag go through a letterbox?
Yes, if the bag is flat enough and the box is under the postal thickness limit. We check the filled bag against the limit for your market.
What board do you use?
E flute for mailers, which takes knocks and prints well; B flute for a kilo or multi-bag shipper.
Do I need void fill?
Not in a box sized to the bag with 5 mm of clearance. Customers dislike it and it costs money.
Can the inside be printed?
Yes, and on a coffee mailer it is worth it — the inside is what is seen at the kitchen table.
Does the box need tape?
Not a self-locking mailer. Shippers are taped.
What is the minimum order?
100 boxes.
Can the box hold a card and a sample too?
Yes, with a board insert that keeps them in place beside the bag.
How do I run a subscription with it?
One box, kept constant; a printed insert card that changes each month; reorder the box quarterly.
Will the bag valve be damaged?
Not in a close-fitting E-flute box. It is loose bags pressed hard in transit that vent.
Kraft or white?
Kraft with one or two colors is the roaster standard and cheaper; white-lined for full color.
Do you keep the die?
Yes, so reorders skip the tooling.
Do you ship outside the US?
Yes, to the United States, United Kingdom, Canada and Australia, quoted in the delivery currency.
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