Custom Fuel Pump Boxes
Custom fuel pump boxes from 100 — cartons with fitted inserts for bare in-tank pumps, complete sender modules and inline pumps, protecting the float arm, the strainer and the electrical connector, with fitment and part number on the panels a counter reads.
A float arm bends and the gauge reads wrong forever
- Board
- 20–24 pt SBS boxboard; E flute for complete modules
- Inserts
- Die-cut board cradle, molded pulp or foam around reservoir and float arm
- Extras
- Kit bag pocket, connector pocket, anti-static bag allowance
Get a price for Fuel Pump 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.
Bare pump, module or inline
| Bare in-tank pump | Slim carton; strainer and kit bag held in a board cradle |
|---|---|
| Complete module | Larger carton or E flute; molded or die-cut insert around the reservoir |
| Inline pump | Compact carton; fittings and clamps in a separate cell |
| Pump with sender | Cavity that keeps the float arm off every wall |
Where the insert does its work
Send us the part, or a drawing with the float arm position, and the insert is drawn from it. Our packaging inserts cut to the part range shows the insert styles we use.
- Cradle the reservoir or pump body so it cannot slide.
- Leave clear space around the float arm, or hold it in a slot at its hinge.
- Keep the strainer sock off the carton wall so it is not crushed.
- Hold the connector and wiring in a pocket, away from the pump body.
Static-sensitive senders
Modern modules include a level sender and sometimes electronics. Where your supplier specifies it, the module goes into an anti-static bag inside the carton, and the insert is sized to take the bag. Tell us at quote so the cavity leaves room for it.
Panels the counter uses
Part number on the front and both ends; vehicle fitment or a pointer to the fitment guide; flow rating and voltage where you publish them; barcode on a matte patch. Many brands also print installation cautions supplied by their engineers — we print them exactly as supplied.
Fuel Pump 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
- 20–24 pt SBS boxboard; E flute for complete modules
- Inserts
- Die-cut board cradle, molded pulp or foam around reservoir and float arm
- Extras
- Kit bag pocket, connector pocket, anti-static bag allowance
- Panels
- Part number front and ends, fitment, ratings, barcode
- Full color; matte laminate for handling
- Delivery
- Flat; inserts flat or pre-formed
- 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 fuel pump 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.
280–350gsmMetalized 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: fuel pump 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 Fuel Pump 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 fuel pump 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 do you protect the float arm on a fuel pump module?
The insert leaves clear space around the float arm or holds it at the hinge so it cannot bend.
Do you make boxes for bare in-tank pumps?
Yes, slim cartons with a cradle for the pump and a pocket for the strainer and kit bag.
Can the box hold a complete fuel pump assembly?
Yes, usually in E flute with a molded or die-cut insert around the reservoir.
Do you make inline fuel pump boxes?
Yes, compact cartons with a separate cell for fittings and clamps.
Can the module go in an anti-static bag?
Yes. We size the insert to take the bag if your supplier specifies one.
What information goes on the box?
Part number front and ends, fitment, flow and voltage ratings, and a barcode.
Can you print installation warnings?
Yes, exactly as your engineers supply them.
Which insert material is best?
Die-cut board for most pumps; molded pulp or foam for heavy modules and premium lines.
Can one carton fit several pumps?
Often, if the pumps share a size. The insert may change while the carton stays the same.
Do fuel pump inserts arrive formed?
Board inserts arrive flat and fold in; molded pulp and foam inserts arrive ready to use.
What is the minimum order for fuel pump boxes?
100 boxes per size. Pumps that share a carton but need different inserts can be ordered together.
How long do fuel pump boxes take?
The insert is sampled around your pump or module first, then the run is scheduled. We give a date with the quote.
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