Custom Tumbler Boxes

Inserts for Lids, Straws and Handles

An insert holds the tumbler upright or on its side and keeps it from moving. Card inserts with a cradle or a top collar are economical and work well for most tumblers. Corrugated inserts give extra cushioning for heavy stainless steel. Foam or pulp inserts are best for fragile glass tumblers.

Straws and spare lids can sit in a slot alongside the tumbler or in a separate compartment. Tumblers with handles need extra width, so measure from the outside of the handle to the far side of the tumbler body. Send us a tumbler sample or exact dimensions and we will design the insert to fit.

Pulp inserts are worth considering for glass, as they cradle the curve of the tumbler and spread impact evenly. They also look natural and fit well with brands that favour a simple, uncoated look.

Common Tumbler Sizes

Tumblers are usually sold by capacity in ounces. A 12 oz tumbler is about 85 mm wide and 140 mm tall with its lid. A 20 oz tumbler is about 90 mm wide and 190 mm tall. A 30 oz tumbler is around 100 mm wide and 210 mm tall. A 40 oz tumbler with a handle can be 135 mm wide including the handle and 280 mm tall with the straw lid.

Add 3–5 mm of clearance on each dimension for card inserts, or more for corrugated cushioning. If you sell several sizes, keeping the same box design across sizes builds a strong family look on the shelf.

Measure the real product rather than relying on a listing. Lids, straws and handles vary between brands even at the same capacity, and a few millimetres can decide whether a lid fits under the box flap.

Tumblers that lie on their side need a box closer to the tumbler's length than its height, with a cradle at each end. This layout suits mailer boxes, where a lower, flatter box is cheaper to post and less likely to be crushed in a sorting machine. Upright layouts suit retail shelves, where the box stands like the product. The allowances follow our guide to measuring a product for packaging, with the lid treated as part of the product.

Board, Print and Finishes

Retail tumbler boxes are usually made from 350–400 gsm folding board for smaller tumblers, or E-flute corrugated board for heavier tumblers and shipping. White board gives the brightest colours; kraft suits outdoor and adventure brands. Rigid boxes made from wrapped greyboard suit premium ranges.

Full-colour print can show the tumbler in use, the colours available and key features. A matt or soft-touch lamination looks modern; gloss makes colours bold. Foil logos and spot gloss highlights add a premium touch.

Print the tumbler's main features on the side panel: how long it keeps drinks hot or cold if you have tested it, what lid style it has and whether it fits a car cup holder. Keep claims accurate and specific to your product.

A clear image of the tumbler on the front panel helps buyers who see the box before the product, such as on a high shelf or in an online listing.

Drinkware Labels and Engravers

Drinkware brands selling online and through retailers are the main buyers. Personalisation and engraving businesses use them to package customised tumblers for gifts and events. Gift shops and homeware stores use them for own-label drinkware. Coffee shops sell branded travel mugs in boxes, and corporate merchandise suppliers use them for branded tumblers for staff and clients.

Sports clubs and gyms order printed tumblers in boxes for members and merchandise stands, and schools and charities sell them as fundraising items. Brands that print the bottle as well as the box order water bottle stickers in the same artwork for the drinkware.

Measure With the Lid On and the Handle Out

Tumbler boxes go wrong on the two parts people forget: the lid and the handle. Fit the lid, push the straw in if it ships that way, and measure the full height; then measure the width across the body including any handle, since a 40 oz handled tumbler is 40 mm wider than its body. Add 5 mm each way for a card cradle or 10 mm for corrugated cushioning, and say whether the tumbler ships standing or lying down, because the insert is cut differently. If you sell three capacities, send all three sets of figures and ask whether one box with three inserts beats three boxes. Ceramic mugs that ship the same way follow the printed mug boxes with a handle cradle.

Email the dimensions, style, insert type, artwork and quantity per size, and a custom quote comes back within one working day, followed by a free design proof showing the insert. Once the proof is approved the boxes take 4 to 7 working days to make and ship flat by free tracked courier, reaching UK mainland addresses in 2 to 3 days. Should a box or insert arrive damaged or mis-cut, send a photo within 10 days and we replace or refund it.