Our Custom Lighter Boxes are designed to deliver compliance-ready packaging without sacrificing brand presence: combining premium materials, precision engineering, and fully bespoke print to elevate your brand at every touchpoint
Free Shipping Across USA
Offset/Digital printing
Free Design Support
Custom Finishing
Our Custom Lighter Boxes represent the intersection of material science and brand design: engineered to protect your product through every stage of its journey while making an impression that drives loyalty, repeat purchases, and social sharing. Designed specifically for tobacco manufacturers, cigar brands, luxury cigarette producers, these boxes are built to deliver compliance-ready packaging without sacrificing brand presence.
Every Custom Lighter Boxes we produce starts with a conversation about your product, your brand, and your customer. The structural design is engineered to your exact dimensions: no unnecessary bulk, no inadequate protection. The exterior print surface is treated to deliver the colour accuracy, finish quality, and tactile experience that reflect the value of what's inside. Whether you're launching a new product or scaling an established line, our Custom Lighter Boxes are manufactured to the same exacting standards at every order volume.
We understand that packaging is never a standalone decision: it is part of a brand ecosystem. Our Custom Lighter Boxes are designed with that ecosystem in mind, complementing your product design, brand guidelines, and customer experience strategy. The result is packaging that doesn't just work: it works for your brand.
Compliance | Designed to accommodate regulatory warning panels, graphic health warnings, and track-and-trace codes |
Freshness | Foil-lined interior available for moisture and freshness preservation |
Structure | Flip-top, slide, hinge-lid, and shoulder box configurations |
Sizes | Standard 20s, 25s, and custom count configurations |
MOQ | LOW MOQ (regulatory minimum typically applies) |
Lead Time | 10–15 business days (compliance review included) |
Track & Trace | UID/serialisation code panels available |
Board & Structural Materials
◆ Premium SBS Paperboard 300–400gsm
◆ Coated Duplex Board
◆ Rigid Board (cigar boxes)
◆ Specialty Foil-Lined Board
Interior, Lining & Insert Options
◆ Foil-lined interior (freshness barrier)
◆ White interior with capacity markings
◆ Slide tray insert
◆ Moisture-resistant inner liner
Available Print Finishes
◆ Gloss Lamination
◆ Matte Lamination
◆ Soft-Touch Coating
◆ Gold/Silver Foil Stamping
◆ Embossing
◆ Spot UV on brand logo
Print Method | Description & Best Use |
Digital Printing | Ideal for short runs, prototypes, and personalised or variable data printing. Up to 4-colour CMYK process. Fast turnaround with no plate costs. Best for: samples, limited editions, and test runs. |
Offset Lithography | The gold standard for colour accuracy and consistency on medium to large volume runs. Pantone PMS spot colour matching available. Best for: retail, brand-critical, and premium packaging where colour precision matters. |
Flexographic Printing | Cost-efficient for high-volume corrugated, kraft, and food packaging. Up to 6-colour print. Best for: corrugated food boxes, pizza boxes, and high-volume retail packaging. |
Colour System
CMYK (4-colour process) as standard. Pantone PMS spot colour matching available on all offset print runs. White ink available for printing on kraft, black, and dark-coloured boards.
Print Resolution
300 DPI minimum at final print size for digital. Equivalent photographic-quality resolution on offset lithography.
Artwork File Requirements
Preferred format: PDF (press-ready). Also accepted: AI, EPS, PSD. Minimum resolution: 300 DPI at 100% print size. Bleed allowance: 3mm all sides. Safe zone: 3mm inside trim edge. Embed all fonts and linked images before submitting.
Proofing & Approval
A full-colour digital PDF proof is provided for every order before production commences. Physical die-line and printed samples available on request (additional lead time applies). Approval required before plates are produced.
Category Note: All artwork must comply with applicable tobacco packaging regulations. Graphic health warning space and regulatory panels are built into the template. Plain packaging compliance options available for applicable markets.
Yes, we offer sample kits and paid custom samples so you can verify the structure and print quality before a larger run.
Our minimum order quantity starts as low as 50 units for standard boxes, allowing you to test the market effectively.
You need a print-ready file (AI or PDF). If you don't have a designer, you can download our dielines and use Canva or Adobe Illustrator to place your logo. We review every file before printing.
Standard production takes 7-10 business days. Shipping time depends on your location and the shipping method selected at checkout.
Absolutely! We specialize in engineered custom packaging. Please fill out the custom quote form below with your specific dimensions.
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Structure Packaging engineers premium custom solutions, turning your unboxing into a brand asset. We are committed to load-bearing integrity, sustainable materials, and factory-direct speed with every shipment.