Custom Luxury Chocolate Boxes
A selection box is an insert with a lid on it. The box is the frame, the insert is the product, and everything that makes one of these feel expensive — the spacing, the reveal, the sense of order — happens in a tray a few millimeters deep.
- Builds
- Rigid lid and base, magnetic hinged, drawer boxes, two-layer builds
- Board
- 1.5–2 mm grayboard, wrapped
- Inserts
- Vacuum-formed, molded pulp, die-cut card, individual paper cases
Get a price for Luxury Chocolate 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.
The insert decides the price the box can carry
Pieces spaced generously, in a straight grid, each in its own well, read as a considered set. The same chocolates in a loose tray with a paper case each read as a bag of candy that happens to be in a box.
That difference is spacing rather than money. A tray with 4 mm between pieces costs the same as one with 1 mm and looks like a different product.
That tray is a cavity insert cut to your pieces, and it is quoted as its own line because it is its own decision.
Leave a finger recess beside at least one row. A tightly fitted first piece is genuinely hard to lift out, and that is the first thing the customer experiences.
Insert materials, and what buyers now expect
Paper cases are the flexible answer: a single box and tray can hold a fifteen-piece or a twenty-four-piece assortment, and the range changes without new tooling.
| Vacuum-formed plastic | The traditional choice; best fit, hardest to defend now |
|---|---|
| Molded pulp | Holds irregular pieces, single material, needs volume for tooling |
| Die-cut card | Recyclable with the box; fine for uniform pieces, poor for domes |
| Individual paper cases | No tooling at all, and one box then holds anything |
Nothing printed touches the chocolate
Cocoa butter migrates into board, and printing inks are not intended for direct food contact. A printed tray under bare chocolate is wrong in both directions — the chocolate marks the board and the board is not a food surface.
A food-grade liner, a paper case per piece, or a food-grade coated tray solves it. The barrier reasoning across the category is in our chocolate packaging notes.
It has to survive being a gift
- Bought as a present, so it is carried, wrapped, and often posted before it is opened.
- A rigid lid and base survives that; a folding carton arrives with soft corners.
- A ribbon pull under the tray lets the whole layer lift out without tipping the box.
- A tamper seal torn across the lid ruins the gift — put tamper evidence on the outer wrap.
Layers, and the second reveal
A two-layer box with a lift-out tray gives a second moment of discovery, which is most of why the format exists at a premium price. It also doubles the insert cost and adds depth that has to be structurally supported.
The upper tray needs a lip or a ledge to sit on, and that ledge has to carry the weight of a full layer of chocolate without sagging into the layer below.
Luxury Chocolate 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
- Builds
- Rigid lid and base, magnetic hinged, drawer boxes, two-layer builds
- Board
- 1.5–2 mm grayboard, wrapped
- Inserts
- Vacuum-formed, molded pulp, die-cut card, individual paper cases
- Food contact
- Food-grade liner, case or coated tray — never bare printed board
- Features
- Ribbon pulls, lift-out trays, printed tray surfaces
- 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 luxury chocolate 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: luxury chocolate 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 Luxury Chocolate 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 luxury chocolate 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 the minimum order?
100 boxes, with the insert quoted alongside.
What makes a selection box look expensive?
Spacing. A tray with generous, even gaps between pieces costs the same as a tight one and reads as a different product.
Can chocolate sit on a printed tray?
No. Cocoa butter migrates into board and inks are not for food contact — use a liner, a case or a coated tray.
Can one box hold different piece counts?
With individual paper cases, yes. The box and tray stay the same and the assortment changes without new tooling.
Is a two-layer box worth it?
It buys a second reveal, which is most of the premium. It also doubles the insert cost and needs a supporting ledge.
Will the chocolate survive posting in summer?
No packaging refrigerates. A light box, clearance around each piece and a corrugated outer buy hours, which is usually what matters.
What makes a selection box look expensive?
Spacing. A tray with generous, even gaps between pieces costs the same as a tight one and reads as a different product.
Can chocolate sit on a printed tray?
No. Cocoa butter migrates into board and inks are not for food contact — use a liner, a case or a food-grade coated tray.
Can one box hold different piece counts?
With individual paper cases, yes. The box and tray stay the same and the assortment changes without new tooling.
Is a two-layer box worth it?
It buys a second reveal, which is most of the premium. It also doubles the insert cost and needs a ledge strong enough to carry a full layer.
Same range
