Custom Cigar Boxes

Inserts That Hold Each Cigar

Cigars should lie flat and still. A simple card insert with shallow channels, or a series of dividers, keeps each cigar in its place so they do not roll against each other and lose their wrappers. For a single row, a raised platform makes the cigars sit closer to the lid, so they are on show the moment the box opens.

Gift boxes often include a space for a cutter, lighter or matches. These are heavier than cigars and need their own fitted cavity so they do not slide across and damage the cigars. If you plan to include accessories, send their dimensions with the cigar sizes.

We usually line inserts with paper rather than fabric to avoid odours. Many cigar makers wrap cigars individually in cellophane or tubes before boxing them, which adds a further layer of protection.

Materials and Finishes for Custom Cigar Boxes

Rigid greyboard wrapped in printed or textured paper is the most popular construction for premium boxes. Wood-effect papers give a cabinet look without the weight, while deep colours such as burgundy, navy, black and forest green paired with gold foil feel traditional and luxurious. Kraft and natural textured papers suit artisan and boutique brands.

Folding boxboard is used for lighter, more affordable cartons and for samplers. It can be printed in full colour and finished with foil and embossing, giving a premium look at a lower cost and weight.

Foil stamping, embossing, debossing and spot UV are the classic finishing touches: a foil logo on the lid, embossed borders, a debossed crest and a printed paper band or seal across the lid all help a box look the part.

Inside the lid is worth printing too. A pattern, a short story about the blend or the origin of the leaf, or a simple signature from the maker turns the moment of opening into part of the experience. Enthusiasts often keep good boxes for storing accessories, letters or keepsakes, so a well-made interior keeps your brand in view for a long time. Matching printed cigar bands in the same foil finish the presentation inside the lid.

Sizing to Ring Gauge and Length

Cigars are measured by length and ring gauge, the diameter expressed in sixty-fourths of an inch. Convert both to millimetres when you send us your sizes: a robusto, for example, is roughly 125 mm long with a diameter of about 20 mm. Add a little space in each channel so cigars can be lifted out without catching, and a few millimetres at each end for the insert walls.

If your range includes several vitolas, a box that holds the largest size with adjustable inserts can cover more than one cigar. For mixed samplers, each channel can be sized individually.

Depth depends on whether cigars sit in one or two layers. Two layers save width but make the bottom layer harder to reach, so most retail boxes use a single row or a single layer.

Compliance Space on the Box

Tobacco packaging must carry the warnings and information required by current regulations. We are not able to advise on the wording, but we will lay out your artwork so the required areas fit at the correct size and position, and we print exactly what you supply. Plan these areas early, because they affect where your branding can sit, particularly on smaller boxes.

If you sell through specialist retailers, ask them about any additional labelling or barcode requirements before finalising your artwork.

Leaving a margin around those areas also stops foil or embossing from crowding them, which keeps the box looking deliberate rather than cluttered.

Requesting Cigar Box Pricing

Send your cigar sizes, the number per box, the style and quantity. A custom quote comes back by email within one working day, with minimums kept low and quoted per job, which suits boutique brands and limited releases. Card boxes start from £0.25 each, with rigid boxes priced to build and finish.

Your free design proof lets you check every panel before printing. Once signed off, production takes 4–7 working days and free tracked UK mainland delivery brings the boxes to you in 2–3 working days. Should any boxes arrive misprinted or damaged, report it within 10 days to receive a reprint or a refund.