Custom Sleeve E-Liquid Boxes

Sizing for Common E-Liquid Bottles

E-liquid bottles come in a few familiar formats: small 10 ml bottles, larger shortfill bottles that leave room for a nicotine shot, and wider 100 ml or larger bottles for mixing. Each has a different height and diameter, and the cap and dripper tip add to the overall height, so measure the bottle as sold rather than relying on the label volume.

Allow a small clearance around the bottle in the insert, and remember the tray walls and the sleeve each add thickness to the outside size. If you sell several bottle sizes, a single sleeve design scaled to each size keeps the range consistent while each pack fits its bottle snugly. Our guide to measuring a product for a box covers bottles with dropper caps.

Choosing Board Weight and Colour

Sleeve boxes are made from folding boxboard, usually somewhere around 350 gsm for the sleeve and a similar or slightly lighter board for the tray. That gives a firm feel without making the pack bulky. A black board through the core means the edges stay dark when the sleeve is cut and folded, which looks cleaner on a black design than white board printed black.

Kraft board is an option for brands with a craft or natural style, and metallic board can give a whole range a reflective finish. For the tray, a solid colour often looks best, especially when it contrasts with the sleeve, as the colour flash when the drawer opens becomes part of the brand.

If you are unsure about stiffness, ask for a plain sample of the construction before committing to print. Holding the pack with a bottle inside is the quickest way to judge whether the board feels right for your price point. Board weights are compared in the board and card types guide.

Making Room for Product Information

E-liquid packaging has to carry certain information depending on what is inside, which can include warnings, ingredient lists, nicotine content and batch details. That text needs space, and on a small pack it can easily crowd the design. Plan where it will sit from the start rather than squeezing it in at the end.

A common approach is to put the brand and flavour name on the front of the sleeve, with mandatory text on the back and base. A sleeve with a printed tray gives you even more room, because extra information can go inside the tray or on its base. We cannot advise on what your products legally require, but we will make sure the areas you specify are laid out clearly and printed at a readable size. Pod kits sold beside the liquids use the vape pod boxes with the same panels.

Print and Finish for the Vape Shop Shelf

Bold flavour artwork is the norm in e-liquid, and full-colour printing on a gloss laminate makes fruit, dessert and menthol designs look vivid. Brands that want to signal a more grown-up range often choose matt black or soft-touch lamination with a foil logo, which gets noticed precisely because it is quieter than the packs around it.

Spot UV on the flavour name or an illustration gives contrast on a matt sleeve. Metallic board under the print can add shimmer to a whole range without a separate foil step. If you have a flavour family, colour coding the sleeves while keeping the layout identical makes it easy for customers to find their favourite on a wall of products.

Hold a Blank Tray With a Bottle Before Printing

A sleeve pack is judged in the hand, so ask for a plain sample of the tray and sleeve in the size you think you need and put a filled bottle in it. The drawer should slide out with one finger and stop before it falls, the sleeve should hold its shape when the tray is out, and the board should feel right for the price on the shelf. If a shortfill ships with a nicotine shot, test with both in the tray. Then settle the information panels and send the bottle sizes with the artwork.

A free proof of both the sleeve and the tray is sent before anything is printed, and a custom quote comes by email within one working day. Production takes 4 to 7 working days after approval and delivery is free and tracked to UK mainland addresses in 2 to 3 working days; anything misprinted or damaged reported within 10 days is reprinted or refunded. Brands launching several flavours at once run them as versions of one sleeve. Shops that need child-resistant closures use the child-resistant e-liquid boxes with locking tabs instead.