Custom Coffee Pod Boxes with a Tuck Top Lid

Who buys printed coffee pod cartons?

Pods have made it easy for small roasters to sell their coffee to people who no longer use a grinder. The capsule itself is plain, so the box does the selling.

We make pod boxes for a growing set of UK businesses.

• Speciality roasters adding a capsule line beside bags of beans
• Cafés selling their house espresso in pods to take home
• Coffee subscriptions posting a monthly selection
• Office suppliers boxing pods under their own name
• Gift sellers making tasting boxes with several roasts

The carton holds pods that are already sealed. We make the outer box and any card insert, not the capsule.

Why does a tuck top suit coffee pods?

On a tuck top pod box, the lid is folded from the back panel. It folds over the opening and a flap tucks in behind the front panel, often with small dust flaps at the sides.

That makes the box open like a lid rather than at one end. Lift it and every capsule is on show at once, as in the orange carton in our photos with ten pods sitting in two rows.

It also means people can take one pod at a time and close the box again. The lid stays attached, so the box can live in a kitchen drawer until it is empty.

Our tuck top boxes page covers the lid in more depth.

What size box fits ten coffee capsules?

Small single-serve capsules are roughly 37 mm across and 29 mm deep. In one row of ten, the inside length is about 190 mm, with 40 mm of width and depth.

Laid out two by five, the box becomes shorter in height and wider: about 190 × 76 × 32 mm. Larger pods for other machines can be 50 mm across or more, so the sizes change a lot.

Measure your own capsule across the rim and from the rim to the base. Rims are the widest part and decide how close pods can sit.

Our tuck box measuring guide shows how to add clearance to rows and grids.

Row, grid or stack: how should pods sit?

For grids, a card insert with round holes keeps each capsule upright. Without one, pods tip over as the box empties.

Do coffee pod boxes need an insert?

A single row of capsules wedged end to end holds itself in place. A grid of ten in a shallow box usually needs an insert.

The insert is a flat card panel with round holes punched where each capsule sits. The pod drops in rim up and stays there, even once the box is half empty.

Print the insert in a contrast colour, like the orange tray in our photos, and the box looks finished the moment it is opened. Inserts are quoted as an option.

How do you print a range of coffee roasts?

Most roasters print one layout and change a colour per roast, with the roast name and strength on the front. A strength scale of dots or beans along the side is easy to read at a glance.

Our photos show the range of looks: a cream box with a single word on the side, brown and white roast boxes with a cup logo, and a bold navy and gold carton for a cosmic-themed brand.

Use the back for tasting notes, weight per pod, how many pods are inside and your contact details. The inside of the lid is a good spot for a short note to the drinker.

Which board and finishes suit coffee pod packaging?

Our default for pod cartons is 350gsm white SBS. Kraft and other boards can be quoted when you ask.

White SBS gives strong browns, creams and oranges. Kraft suits a roastery look printed in black or white ink.

Matt lamination is a safe choice and hides scuffs. Gold foil on a dark lid catches the light on a shelf. Spot UV can pick out a bean pattern or the roast name without changing the whole box.

There is more detail in our guide to tuck box finishes.

How are coffee pod boxes delivered and packed?

The cartons come flat. Fold up the sides, lock the base, drop in the insert and the pods, then close the lid and tuck the front flap.

A single-row box slips easily into a slim mailer, which suits subscriptions and refill orders. Grid boxes are wider, so check them against your postal boxes before you order.

Capsule cartons need 4–6 business days on press after your proof sign-off. They then travel to you free, tracked, in 2–3 business days anywhere in the UK.

Can a pod box become a tasting set?

Yes. A tasting set usually holds two or three pods of several roasts, so a new customer can try the range before buying a full box.

The simplest tasting build is a wide tuck top carton whose insert is punched for six or nine pods. Print the roast names on the insert, beside each hole, so nobody mixes them up.

Another route is several small boxes, one per roast, packed into a larger outer carton. That costs more but gives each roast its own printed box to keep.

Tasting sets make good gifts for birthdays, Father's Day and thank-you hampers. Tell us the pod count and layout and we size the box around it.

What are common mistakes with pod boxes?

• Measuring the capsule body instead of the rim, which is wider
• Ordering a grid box without an insert, so the pods fall over
• Choosing a box too deep for the pods, so they rattle in the post
• Making every roast nearly the same colour
• Forgetting to print how many pods are inside

How do you order coffee pod boxes?

1. Lay out your pods in the row or grid you want and measure the block.
2. Tell us the quantity, board, finish and whether you want an insert.
3. You receive a written quote; capsule boxes start from £0.25 per unit; the insert and finish set the final figure.
4. Our designers set your artwork onto the dieline and send a free proof.
5. Approve it, and your boxes are made and delivered free in the UK.

When you are ready, send your sizes on the coffee pod box quote form.