Custom Yoga Mat Boxes

Measuring the Rolled Mat

Roll the mat as tightly as it will be packed and secure it with a strap or elastic. Measure the width of the mat, which becomes the length of the box, and the diameter of the roll at its widest point. Thick mats of 6 mm and more roll to a much larger diameter than thin travel mats, so measure each mat in your range rather than assuming one box fits all.

Add a few millimetres to the diameter for easy packing, and a little extra length if you include a strap, a cleaning spray or a pair of blocks. If the box will hold accessories, tell us what they are and we will add a card insert or partition at one end so nothing slides along the roll.

Different colours of the same mat usually share a box size, so you can order one box design and change only a colour swatch or a sticker on the end panel. That keeps your packaging simple even when you sell a mat in many colours. Our guide to measuring a product for a box covers rolled items.

Board, Print and Finish for Fitness Brands

White folding board takes full colour photography well, which suits brands that show the mat in use on the box. Kraft board and kraft corrugated suit natural, calm brands selling cork, jute or rubber mats, and they look good with one or two colour print.

Matte lamination gives a soft, understated look in keeping with most yoga brands, and soft-touch adds a pleasant feel when the box is carried. Foil is used sparingly: a small foil logo on an otherwise quiet design looks refined. Keep the design calm and spacious rather than busy, as most wellness customers respond to restraint. Soft-touch lamination and a small foil mark are compared in the print and finish options guide.

Bundles and Starter Kits

Many studios and brands sell a starter kit: a mat, a strap, two blocks and perhaps a towel. A wider box with a partition lets the rolled mat sit on one side and the blocks stack beside it, with the strap tucked into a slot. That turns several products into one gift-ready package with a single price, which works well for new students and for corporate wellbeing programmes.

Studios that sell own-brand mats to members can add a printed card inside the lid with a welcome note, a class timetable link or a short care guide for the mat. Telling customers how to clean and store a natural rubber mat reduces complaints and helps the mat last longer. Protein and supplement samples added to a kit are boxed on the sports nutrition boxes for samples page.

Stock, Storage and Display

Long boxes take up space, so they arrive flat and are folded as needed. Corrugated mailers fold in seconds with tuck ends and no tape. If you store finished stock, square-section boxes stack neatly on pallets and shelves without rolling, and a printed end panel showing the colour and thickness makes picking easy.

In shops, boxes can stand upright in a floor display or lie in a stack. If they will stand, print the brand and mat colour on the top end as well as the sides, because that end is what shoppers see when looking down into a display bin. Premium mats sold in a lidded box use the rigid sports boxes for premium kit.

Roll the Mat Tightly, Then Measure the Diameter

A yoga mat box is sized by the roll, and the roll depends on who rolls it. A 4 mm mat rolled tightly is about 100 mm across; rolled loosely by a customer it is 130 mm, and a box drawn to the first will not take the second as a return. Roll the mat the way your warehouse will, with the strap on if it ships with one, measure the diameter and the length, and add 10 mm to each.

Share the rolled diameter, the mat width, any accessories and the quantity per colour, and a custom quote comes by email within one working day; minimums are worked out per job, so a new mat brand or a single studio can order a sensible first batch. The free design proof shows the box flat and folded with the artwork in place. Production takes 4 to 7 working days after approval and free tracked delivery to the UK mainland follows in 2 to 3 working days; boxes that arrive misprinted or crushed are reprinted or refunded if reported within 10 days. Blocks and straps sold separately sit in the sports boxes with display windows.