Custom Five Panel Hanger Boxes
Custom five panel hanger boxes — the fifth panel folds over the top and doubles the hang tab — sized to your product from 100. Stronger on the hook than a single tab, still one piece. Dieline and price the same working day.
The fifth panel is the reinforcement
- Board
- 18–20pt folding boxboard; 24pt on request
- Builds
- Five-panel hanger with tuck or crash-lock base; window optional
- Hang tab
- Doubled from the fifth panel; Euro-slot, round or sombrero hole
Get a price for Five Panel Hanger 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.
Why the folded panel beats a glued tab
A hang tab glued onto a carton depends on the glue; a hang tab folded from the carton itself depends on the board. The five-panel construction takes the extended panel over the top of the box and glues it face-to-face with the front, so the hole passes through two thicknesses and the top of the box is closed by the same fold. It carries roughly double the weight of a single-panel tab and does not peel.
Products it suits
Anything from about 200 g to 600 g packed weight is the five-panel range. Below that a single tab is enough; above it a plastic hang tab or a slot lower on the box.
- Hardware and small tools — screws, bits, fixings — where the pack is heavy for its size.
- Cosmetics and personal care hanging in a pharmacy, where the tab has to survive months of handling.
- Electronics accessories: cables, chargers, adapters.
- Pet, craft and hobby products sold from peg walls.
How it closes and loads
Because the top is glued shut, the box loads from the bottom and closes with a tuck or a crash-lock base. On a packing line that is a single motion; the box is the right way up as soon as it is closed.
| Top | Closed by the folded fifth panel; glued at the factory |
|---|---|
| Bottom | Tuck flap or crash-lock; the product loads from here |
| Front | Full panel, optionally with a window; the tab sits above it |
| Sides | Standard; can carry a second color band for range coding |
Board weight and the folded top
The fold over the top has to be crisp or the tab leans. 18–20pt folding boxboard folds cleanly at that thickness and carries the load; 24pt gives a stiffer box but a rounder fold. For a heavy product we keep the board at 20pt and add a plastic tab instead of going thicker. Our hang tab boxes with a window panel use the same construction with a display cut-out on the front.
Artwork across the fold
The fifth panel is printed on the outside of the fold, which means the front-facing tab is printed on the same pass as the front. The dieline shows which face is which; the common mistake is to set the tab artwork upside down relative to the front. We catch it on the proof, but placing artwork after the dieline arrives avoids the round trip.
The hang hole is cut after gluing so the two layers align. Ask for a Euro-slot unless the retailer specifies otherwise.
Five Panel Hanger 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
- 18–20pt folding boxboard; 24pt on request
- Builds
- Five-panel hanger with tuck or crash-lock base; window optional
- Hang tab
- Doubled from the fifth panel; Euro-slot, round or sombrero hole
- Load
- Suits ~200–600 g packed weight
- Loading
- From the base; top glued closed
- Full color, tab printed with the front
- Minimum
- 100 boxes
On every job
- Print process
- Digital below about a thousand, offset above it. One side or both, with spot colors where a match has to hold.
- Color
- CMYK as standard. Uncoated and kraft stocks print lighter and warmer; a spot color is the only exact match.
- Tolerance
- Cutting plus or minus 1 mm, creasing plus or minus 0.5 mm, confirmed on a plain sample before the run.
- Tooling
- A cutting die per size, made once and kept. Foil and emboss dies per artwork, also kept.
- Food contact
- Food-grade board and inks where the carton touches food, with the interior left plain.
- Sustainability
- Mono-material board wherever the product allows; recycled-content and FSC stocks; no claim printed the pack does not earn.
- 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 five panel hanger boxes on
A folding carton is one sheet of board, so the board is the product. These are the stocks we run for cartons, what each is good at, and where it lets you down.
Natural kraft
Unbleached folding board. Warm, hides marks, costs least. Mutes color — one or two flat colors print well, photographs do not.
250–350gsm sleeves; 14–24pt cartonsWhite SBS
Solid bleached sulfate: bright, coated, the retail carton standard. Takes accurate color and every finish. Shows scuffs sooner than kraft.
14–24ptWhite lined chipboard
A recycled gray core under a white printing face. Cheaper than SBS and slightly duller; the back of the sheet stays gray.
16–24ptKraft-look coated
A kraft face over a coated inner. The natural look with a barrier behind it — the answer where oil, grease or moisture would mark plain kraft.
14–20ptRecycled-content board
Post-consumer fiber with a gray-brown cast. Right for outers and inner components; poor for bright whites and photography.
16–22ptMicro-flute E and F
A fine corrugated layer where a carton needs structure it cannot get from board — a large panel, a heavy product, a box that ships alone.
E 1.5 mm; F 0.8 mmUncoated and textured
No clay coat, or a linen or laid grain. Print reads softer and warmer; a deboss goes deeper. Photographs do not sit well on it.
280–350gsmMetallised and pearlescent
A metallic or pearl face for a shelf that needs to catch light. Costly, and it fights a photograph — a mark or a pattern suits it better.
16–20ptNot 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.
Every finish here is a decision about light on a shelf, not about luxury.
Matte lamination
Reads considered, hides marks, takes a ballpoint.
Gloss lamination
Lifts color; glares under shop lighting.
Soft-touch
Velvet in the hand; shows fingerprints in a bag.
Hot foil
Real metal leaf — the most reliable premium signal.
Emboss / deboss
Shape with no ink; works in the dark.
Spot UV
Gloss shapes on a matte field.
Uncoated kraft
Warm, natural, mutes color.
Textured stock
Texture in the paper; cannot scuff off.
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 a folding carton so the die comes out right: five panel hanger boxes
Measure the product, not the box it is in now. A carton is built around what has to fit inside it, assembled — cap on, lid fitted, folded if it folds — at its widest point in each direction. Send those three numbers and say which is which.
- Length x width x height
- Internal, always. External dimensions include the board and are what the carrier measures, not what the product needs.
- Clearance
- 2–3 mm a side for a snug fit; more where an insert or void fill goes in. A carton cut exactly to the product is slow to pack and transmits every knock.
- Board thickness
- Heavier board takes internal space from the product. It matters most on small boxes, where four walls of 24pt is a real share of the cavity.
- Varies between batches?
- Glass, textiles, molded parts and cured soap all do. Measure several and build to the largest.
- Cutting tolerance
- Plus or minus 1 mm on folding board. Confirmed on a plain sample before the run.
- Units
- Metric or imperial, as long as you say which. Mixing them in one spec is where mistakes happen.
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 Five Panel Hanger 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 five panel hanger 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.
What is a five panel hanger box?
A folding carton with an extra panel hinged off the back that folds over the top and glues to the front, forming a hang tab two layers thick. The box hangs from a hole through both layers.
How is it different from a normal hang tab box?
The tab is folded from the carton and glued face to face, rather than a single extended panel. It carries about twice the weight and cannot peel off.
How heavy a product can it hold?
Roughly 200 to 600 g packed. Above that we add a plastic hang tab or move the hanging point lower on the box.
Which way does the product load?
From the bottom, because the top is closed by the folded panel. The base is a tuck flap or a crash-lock.
Can it have a window?
Yes, on the front panel below the tab.
What is the minimum order?
100 boxes.
Do they arrive flat?
Yes, glued flat. They pop open, load from the base, and the tab is already formed.
What hole shape do you cut?
A Euro-slot unless the retailer specifies a round or sombrero hole. The hole is cut after gluing so the two layers line up.
Which board do you use?
18–20pt folding boxboard. It folds crisply over the top and carries the load; thicker board makes a rounder, weaker fold.
Can the tab be printed?
Yes, it prints with the front on the same pass. Check the orientation on the dieline before sending artwork.
Will it stand on a shelf too?
Yes. With a flat base it stands, and the folded top reads as a closed box rather than a tab.
Do you send a dieline?
With the quote, before you commit, showing the fold sequence and the hole position.
Same range
