Custom Sandwich Wedge Boxes

Measuring Your Sandwich for the Right Wedge

Make your sandwich as you normally would, cut it diagonally and measure the two halves. The long edge of the triangle sets the width of the pack's base, the height of the triangle sets the pack height, and the thickness of the filled sandwich sets the depth, as the guide to measuring your product explains. Bread sizes vary a lot between bakeries, so measure your own loaf rather than relying on a generic size.

Allow a few millimetres around the sandwich so it slides in without tearing the bread, but not so much that it falls over inside. If you make sandwiches on two or three different breads, you may need two wedge sizes, for example one for standard sliced bread and one for larger artisan loaves.

Bring a sample sandwich to mind when checking the proof. The dimensions on the drawing should match what you measured, with the window large enough to show the cut face clearly.

Board, Window and Food Contact

Wedge packs are usually made from a laminated paperboard with a coated inner surface that resists moisture from fillings and condensation in chillers. A clear film window is fitted to the angled face. Kraft-faced board gives a natural, deli look, while white board shows bright colours and photography more clearly.

Food-contact grade board is available on request, and we will name the proposed board on your custom quote so you can check it against your own hygiene records. If you need specific labelling or allergen information, plan space for it as part of your artwork or for a printed label added on the line.

Some sellers prefer a fully cardboard window or a die-cut paper window for a different look. Tell us what you have in mind and we will advise on how it affects visibility in the chiller.

Branding Small Triangle Panels

A wedge pack has two triangular sides, a back panel, a base and the window face. The back and sides are your branding space, and the print and finish options compared page shows how a colour band prints on kraft against white. A bold logo on one side, a short brand line on the other and a clear panel on the back for a product label is a simple layout that works for most sellers.

Because fillings change daily, most businesses print the box with branding only and apply a label for the sandwich name, ingredients, allergens and use-by date. That way one printed wedge design covers your whole menu. If you sell a fixed range in large volumes, printing the product name directly can give a more premium finish.

Colour-coding packs, for example green for vegetarian or a different band colour for each range, helps customers pick quickly from a busy chiller.

Keep the label area plain and light so printed or handwritten details stay legible under chiller lighting.

Working Efficiently on the Line

Wedge packs arrive flat and are erected before filling. Pre-glued designs pop into shape quickly, and the sandwich is slid in through the back before a tab or flap seals it shut, often on a sheet of printed sandwich wrapping paper. A tamper-evident seal, such as a label across the opening or a tear strip, reassures customers that the pack has not been opened.

Store flat packs somewhere clean and dry. Board can absorb moisture and become harder to erect if left in a damp prep area, so bring them in as needed for each shift.

If you make sandwiches early in the morning for sale through the day, keep a small stock of erected packs ready by the prep bench before the rush starts. It saves fumbling with flat blanks while bread and fillings are out.

Train staff to slide the sandwich in cut face first and press it gently against the window, so every pack on the shelf shows the filling the same way. A consistent display looks professional and helps customers compare fillings at a glance.

Cut Your Fullest Sandwich Diagonally and Measure the Two Halves

A wedge pack is sized from the cut halves, not the whole sandwich. Make the most generously filled sandwich on the menu, cut it diagonally and measure a half: the long edge sets the base width, the triangle height sets the pack height and the filled thickness sets the depth. Bloomer slices usually push you to the wide wedge and deep fillings to the deep-fill size. Decide whether one printed pack with a label panel for the sandwich name, allergens and use-by date will cover the whole menu, which keeps stock to one carton, and whether a tear strip or a sealing label is wanted for tamper evidence.

Send the sandwich measurements, the wedge style, the window preference and your artwork, and a custom quote comes by email within one working day, from £0.25 per pack, minimums low and quoted per job so an independent deli is welcome. A free design proof shows every panel and the window. Production takes 4 to 7 working days after approval and free tracked delivery reaches UK mainland addresses in 2 to 3 working days. Delis that sell salads too usually add printed paper food boats in the same colours.