Custom Popcorn Paper Cones
Custom popcorn paper cones in grease-resistant board with your print, plus a stand or a tray that holds them upright at the counter, from 100. Dieline and price the same working day.
A cone of popcorn is cheaper than a box and looks like more
- Board
- Grease-resistant 250–300 gsm, coated white or kraft; PFAS-free
- Builds
- Rolled sectors, pre-glued cones; fold-over tab or sticker
- Sizes
- 150, 200, 250–280 mm; about 1–4 oz
Get a price for Popcorn Paper Cones
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.
Sizes and what they hold
Popcorn is light, so a cone holds less by weight than it looks. Size to your serving and check it with a plain sample filled from your machine.
| Small, 150 mm | About 1 oz; a taster or a party cone |
|---|---|
| Medium, 200 mm | About 2 oz; the market cone |
| Large, 250–280 mm | About 3–4 oz; the cinema cone |
Board that takes butter
The same grease-resistant board as a popcorn box — the resistance in the sheet, no PFAS — at 250–300 gsm so the cone rolls cleanly and stays stiff. Food-safe inks on the outside; the inside plain. A cone that goes soft in the hand is a board choice, not a popcorn problem.
Rolled or pre-glued
Our cone packaging for food and retail covers the fries and sweet cones built the same way.
- Flat sectors, rolled and glued or taped at the stand — the cheapest, and a few seconds each.
- Pre-glued flat cones that open into shape — faster at a busy counter.
- A fold-over top tab or a sticker for a party cone that is filled ahead.
Stands and trays
A cone cannot stand on its own. A printed board tray with a dozen holes holds filled cones at a counter or on a party table; a single-cone stand suits a cart; a tall display holds empty cones beside the machine. All three are cut from the same board, printed to match, and quoted with the cones.
The stand is what makes the display. A box of cones with no stand ends up lying on the counter.
Artwork that rolls into a spiral
The design is placed on the flat sector and rolls into a spiral, so stripes, patterns and a logo at the rim work best. Full color on coated board; one color on kraft for a market stall. The dieline shows the sector and where the rim and the seam fall.
Popcorn Paper Cones — 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 250–300 gsm, coated white or kraft; PFAS-free
- Builds
- Rolled sectors, pre-glued cones; fold-over tab or sticker
- Sizes
- 150, 200, 250–280 mm; about 1–4 oz
- Full color or 1 color; food-safe; placed on the sector
- Stands
- Tray of 12, single stand, tall display; quoted alongside
- Supply
- Flat sectors or pre-glued cones
- Minimum
- 100 cones
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 popcorn paper cones 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: popcorn paper cones
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 Popcorn Paper Cones 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 popcorn paper cones? 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 much popcorn does a cone hold?
About 1 oz in a small, 2 oz in a medium and 3–4 oz in a large. Popcorn is light, so a cone holds less by weight than it looks.
Will butter soak through?
No — the board is grease-resistant in the sheet, without PFAS, and stays stiff in the hand.
Do cones arrive rolled?
Either as flat sectors you roll at the stand, or pre-glued cones that open into shape.
How do I display them?
In a printed tray with holes, a single-cone stand or a tall display for empty cones, all quoted with the cones.
Can they be printed in full color?
Yes, on coated board. The design is placed on the sector and rolls into a spiral, so patterns and rim logos work best.
What is the minimum order?
100 cones.
Are the inks food safe?
Yes, and the inside is plain.
Can I fill them ahead for a party?
Yes, with a fold-over tab or a sticker to close the top.
Kraft or white?
Kraft with one color for a market stall; coated white for full color.
Can the stand match the cones?
Yes, cut from the same board and printed to match.
Do you send a dieline?
Yes, with the quote, showing the sector, the rim and the seam.
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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