Custom Food Packaging

Sandwich Boxes

Sandwich Boxes built to your specification — your dimensions, your board, your print.

Minimum order: 100 units
Production: 3–5 business days
Construction: folding carton
Delivery: US, UK, Canada, Australia

Sandwich Boxes shown as a finished custom-printed pack

No obligation

Ask for a quote

Name, email, phone and what you are packing and the volumes you run. Attach artwork if you have it. We reply with a specification and a written price, usually within one business day.

What sandwich boxes have to cope with

Sandwich Boxes hold a cut sandwich displayed on its cut face, which is the whole point of the pack. That is the starting point for the specification, because a snug fit that holds the cut face against the window is what keeps the display honest for the whole session.

In service they are used for chiller cabinets in cafés and forecourts, packed at dawn and bought at noon.

Where sandwich boxes are actually used

Sandwich Boxes are specified for chiller cabinets in cafés and forecourts, packed at dawn and bought at noon. A snug fit that holds the cut face against the window is what keeps the display honest for the whole session.

Chiller cabinets in cafés and forecourts, packed at dawn and bought at noon
Shelf display in specialty retail
Subscription and gift sets
E-commerce inner packaging

The substrate for sandwich boxes

14pt board with a window sized and positioned to the cut face, which is the only view that sells the product.

The options we would consider for this format are below; a snug fit that holds the cut face against the window is what keeps the display honest for the whole session.

12pt SBS paperboard
14pt SBS paperboard
16pt SBS paperboard
18pt kraft board
recycled CCNB board

Printing sandwich boxes

Keep print clear of the window frame. A crowded frame makes the sandwich look smaller than it is.

Offset lithography, Digital press, Flexography are all available for this format. Run length usually decides which is cheapest: digital removes the plate cost on short quantities, offset and flexo overtake it at volume.

Finishing sandwich boxes

Keep print clear of the window frame. A crowded frame makes the sandwich look smaller than it is.

Finishes are costed one at a time because each is a separate operation — that way you can see which one is carrying the price.

Gloss lamination
Matte lamination
Soft-touch lamination
Spot UV
Foil stamping
Embossing
Debossing
Aqueous coating

Sizing sandwich boxes

Wedge and rectangular formats sized to a standard loaf cut — commonly 5 × 3 × 3 in wedges.

Send the contents rather than a box size. The window is sized to the sandwich as packed, not as it looks three hours later when the filling has settled.

Holding sandwich boxes before service

The sandwich slumps away from the window during the morning and the display face is no longer visible by lunch.

Paperboard also absorbs moisture from the air until it equalises with its surroundings. If stock sits more than about six weeks in unconditioned space, a moisture-resistant coating is worth its small premium.

Getting artwork press-ready

Supply artwork on the dieline we send you, with 3 mm bleed past every trim edge and all text held 4 mm inside the fold lines.

Supply a print-ready PDF or vector file with fonts outlined and images at 300 dpi. Our prepress team checks every file before a proof is issued. The check that catches most files is type sitting too close to a crease, which is easier to move at layout than at proof.

Ordering sandwich boxes

Start with dimensions and quantity. If you already run something similar, a physical sample tells us more in a minute than a specification does in a page.

A dieline template follows, sized to your product. Prepress checks your artwork against it and issues a proof; nothing runs until you sign that off.

What buyers get wrong with sandwich boxes

The window is sized to the sandwich as packed, not as it looks three hours later when the filling has settled.

The rest of these come up often enough across the format to be worth stating plainly.

Specifying board weight without saying how hot or greasy the contents are.
Forgetting that a pack carried at an angle in a courier bag behaves differently to one on a counter.
Choosing a vented lid for a dish that needs to stay hot, or a sealed one for a dish that needs to stay crisp.
Ordering a year of stock that then sits through a humid summer.

Checking it before you commit

A plain structural sample is the cheapest way to find a fit problem — far cheaper than finding it across a full run.

Sample costs are normally credited against the production order.

Reference

Sandwich Boxes at a specification level

Product	Sandwich Boxes
Category	Custom Food Packaging
Construction	Die-cut, creased and seam-glued
Board thickness	12pt – 18pt depending on product weight
Ships as	Flat-packed, glued one seam
Materials	12pt SBS paperboard, 14pt SBS paperboard, 16pt SBS paperboard, 18pt kraft board
Printing	Offset lithography, Digital press, Flexography
Finishes	Gloss lamination, Matte lamination, Soft-touch lamination, Spot UV, Foil stamping
Minimum order	Minimum order is 100 units on any format, and unit cost falls sharply as the quantity rises.
Lead time	3 to 5 business days after artwork approval
Shipping	Across the US, UK, Canada and Australia

What you get

Where this holds up on a line

Sized to the contents

Wedge and rectangular formats sized to a standard loaf cut — commonly 5 × 3 × 3 in wedges.

The failure worth avoiding

The sandwich slumps away from the window during the morning and the display face is no longer visible by lunch.

Where it is used

Specified for chiller cabinets in cafés and forecourts, packed at dawn and bought at noon.

The detail that decides it

A snug fit that holds the cut face against the window is what keeps the display honest for the whole session.

This format sits in our custom food packaging range, alongside 33 other made-to-order formats.

Answers

Ordering sandwich boxes: the usual questions

Specification, minimums and lead times for sandwich boxes.

Are these food-contact compliant?

We specify food-contact compliant boards and inks where the pack touches food directly. Tell us whether contact is direct or through a liner for sandwich boxes, because it changes which stocks are available to you.

How do you stop grease showing through?

A grease-resistant coating or a greaseproof liner. Untreated board will always strike through eventually with hot, oily food — that is a property of the material rather than a quality fault, and it is inexpensive to design out.

Do sandwich boxes arrive flat or assembled?

Flat and glued along one seam, so they pop open on your packing line. That keeps freight cost down considerably compared with a pre-assembled structure.

How long do sandwich boxes take to produce?

3 to 5 business days after artwork approval, plus freight. Folding carton runs with applied finishes can take longer because each finish is a separate pass, and we confirm a firm date in writing with the quote.

What do sandwich boxes cost?

Prices start from $0.30 per piece for large-volume orders. For this format the biggest levers are quantity, print route, board grade and how many finishing passes are involved. We quote each element separately so you can see where the money is going. Finishing passes are the lever buyers most often underestimate: each one is a separate run through the line.

Can I see a sample first?

Yes. We can send a plain unprinted sample so you can check the fit and structure, or a printed prototype for colour and finish. Sample costs are normally credited against the production order. Worth running a few through your actual line rather than checking them by hand: fill speed and hot contents find fit problems that a desk check does not.

Can you match packaging we already use?

Send the current specification or a physical sample and we will quote to match it rather than proposing an alternative you would then have to re-approve internally. Tell us the coating on the pack you are matching too. Grease and moisture resistance are not visible in a sample and they change which stocks we can quote.

Where do you deliver?

All 50 US states, the United Kingdom, Canada and Australia, on the same timeline everywhere: 3 to 5 business days of production after artwork approval, then 5 to 7 business days in transit. Every run is made to order and shipped directly to your address rather than pulled from stock, so you receive current production rather than whatever has been sitting in a warehouse. Freight is costed separately by weight, volume and destination. If stock is going into a kitchen or a service counter rather than a warehouse, tell us — case sizes that a single person can lift and store matter more there than pallet efficiency.

Can I order sandwich boxes in a custom size?

Every run is cut to your dimensions — there are no stock sizes here. Send the product measurements rather than a box size and we will build the folding carton around them, then send a dieline template you can design onto.

What happens after I approve the quote?

We issue a dieline template sized to your product, prepress checks your artwork against it, and a proof comes back for sign-off. Nothing runs until you approve that proof, and folding cartons then take 3 to 5 business days.

Can you hold the specification for repeat orders?

Yes. Once a first run is approved we hold the board, structure, dimensions, print method and finishes against your account, so a reorder references the same specification exactly rather than being re-derived. The board and coating are held together, so a reorder cannot quietly arrive on a stock with different grease resistance.

Do you offer recycled or recyclable options?

Recycled grades are available across most of the substrates we run for folding cartons. Recycled content, kerbside recyclability and certified compostability are three different claims though, so tell us which one you intend to print.

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