Custom Roll End Tuck Top Boxes

Board Grades and Flute Sizes

Most roll end tuck tops are made from E-flute corrugated board, which has small, tight flutes. It is thin enough to fold crisply and print sharply, yet strong enough to protect most items in the post. B-flute has larger flutes and gives more cushioning and crush resistance for heavier contents such as glass jars or books.

For very light items, such as a scarf or a pack of cards, a folding boxboard version without flutes can work and costs less, although it offers little protection against heavy parcels stacked on top. The outer liner can be brown kraft, white or mottled white. Kraft gives a natural look and hides scuffs; white shows colours more brightly.

If you are unsure, send us the item and its weight. A quick check of fill weight against the board grade avoids crushed corners once parcels are in the courier network. You can see E-flute and B-flute compared in our board guide.

Print Inside, Outside or Both

A plain kraft outside with a fully printed inside is one of the most popular combinations. The box travels discreetly, which can deter theft, and the customer gets a burst of colour when they lift the lid. Printing the inside lid with a thank-you message, a pattern or a social handle encourages people to share a photo of the opening.

Full outer print turns the box into a moving advert as it passes through sorting depots, communal hallways and offices. If your product is something people prefer to receive discreetly, keep the outside plain and the branding inside.

Digital printing suits short runs and many designs, such as different subscription themes each month. Flexographic print in one or two colours on kraft keeps costs low for larger, consistent runs. White-lined board takes inside print on corrugated so the opening carries a message.

Sizing for the Product and the Post

Measure your product, or the largest combination of products you send, and add room for any insert, tissue or filler. For a snug fit with tissue, add around 5 mm on each dimension. If you use a card insert, size the insert first and then the box around it.

Then check the outer size against postal limits. A mailer under 25 mm deep may qualify as a large letter, while anything deeper is a small parcel. Keeping a box shallow enough to drop into a cheaper postage band can save more money over a year than any saving on the box itself. We can show you the outer dimensions on the proof so you can compare them before you sign off.

For subscription boxes whose contents change every month, size around the bulkiest month you expect and use paper fill in quieter months, rather than ordering a new size each time.

Inserts and Finishing Touches

A card insert with cut-outs holds products in position and gives a tidy reveal. Tear strips along the front make opening easier and show if a parcel has been tampered with. Double-sided tape strips on the tuck flap allow a box to be sealed securely for postage, and a second strip lets a customer return an item in the same box.

Matt or gloss lamination on printed boxes adds resistance to scuffs and damp. Spot colours in your exact brand shade keep the box consistent with your website and other packaging.

Think about packing speed too. A box that takes ten seconds longer to fold and fill adds up to hours across a busy month. Folding a stack of boxes before a dispatch session, keeping inserts pre-folded beside them and placing tape strips on the flap in advance all make packing smoother. If you pack several sizes, printing a small size code on an inside flap helps staff grab the right box without measuring. Products that must not move sit in card inserts with cut-outs sized to the mailer.

Fold a Sample Box Twice Before You Finalise the Inside Dimensions

Roll end boxes lose a few millimetres on each side to the rolled walls, so an inside dimension taken from the product alone can end up tight. Ask for a plain sample in your size, fold it twice to learn the assembly, and pack the product with its insert or tissue before you sign off the dieline. Decide whether the outside stays plain kraft with print inside for a discreet parcel, and whether a peel-and-seal strip and tear strip are needed for returns. Keep the outer depth under 25 mm if the box must post as a large letter. Subscription boxes that change design monthly suit digital print, and a mailer with a fitted card insert stops products moving.

Send the inside dimensions or the product sizes, the board, your print plan and quantities, and a custom quote comes by email within one working day. The free proof shows the dieline with artwork on every panel, including the inside. Production takes 4 to 7 working days after approval, boxes arrive flat by tracked courier to UK mainland addresses, and damaged or misprinted boxes reported within 10 days are reprinted or refunded.