Custom Spray Bottle Boxes Sized Around the Cap and Nozzle

Which products go in a spray bottle box?

Anything sold in a bottle with a mist pump, a fine spray or a trigger. The carton protects the nozzle from knocks and gives you four tall panels to print on.

Our three photos show the spread. A mint green carton lies beside two grey mist bottles, a large and a small. A white and charcoal box stands next to a tall continuous-mist sprayer, with a line drawing of the bottle printed on the front. A lilac box with a crescent moon sits beside an amber bottle with a black pump.

• Pillow sprays and room mists from candle and home fragrance studios
• Facial toners and setting sprays from skincare brands
• Hair mists, detanglers and salt sprays from hair care makers
• Linen and fabric sprays sold in gift shops
• Hand sprays and body mists sold in pairs or travel sizes

Why is the spray head the part to measure?

With most bottles, the glass or plastic body is the widest part. With sprays, that is often not true. A trigger head can stick out well beyond the bottle, and some mist caps have a wide shoulder.

So measure the bottle at its widest point with the cap or head fitted, in every direction. The footprint of the box comes from that number, not the body.

Then measure the height with the cap on. A cap that clicks onto a mist pump adds a few millimetres more than the pump alone, and the carton has to allow for it.

What size carton fits a 100 ml mist bottle?

A typical 100 ml cylinder mist bottle is about 48 mm across and 155 mm tall with its cap. With 3 to 4 mm spare round the footprint and 5 mm over the cap, the inner size lands near 52 × 52 × 160 mm.

Amber Boston round bottles of the same volume are shorter and wider, so they need a different carton. Measure your actual bottle, or send one, and we draw the dieline to suit.

Our measuring guide for tuck box sizes explains clearance in more detail.

Why a reverse tuck for spray cartons?

In a reverse tuck end, the top flap goes in at the back and the bottom flap at the front. It is quick to close by hand, which matters when you are boxing a full batch of mists after filling.

On a tall box, the reverse tuck also keeps the front panel neat at the top edge, where the brand name usually sits.

For larger sprayers, a crash lock base is worth a look. It forms a firm, flat floor as soon as the box is pushed open, which helps a tall bottle stand steady. Our page on auto bottom cartons for tall bottles explains how the base locks.

Can a spray box hold two bottles?

Yes. The mint sample in our photos is built around a pair, a full size and a travel size, lying side by side. That kind of set suits gifts and launch bundles.

For two bottles, a card divider keeps them apart so the caps do not knock together. For a large and small pair, a stepped insert lifts the smaller one so both tops line up.

Measure the two bottles together as they will sit and send that footprint.

How do you stop a spray bottle shifting in the carton?

A cylinder in a square box always has a little play at the corners. For most mists that is fine, as long as the height is right and the cap cannot lift.

For glass bottles, or anything sold by post, a card collar that sits under the shoulder holds the bottle upright and stops it rocking. It is quoted as an option and shown on the proof.

Avoid making the carton too tight around the cap. If the tuck presses on a mist pump, it can trigger a spray inside the box.

Print and finishes for tall spray cartons

Tall cartons give you a long front panel, so use it. The lilac sample runs its product name up the side, with a moon and wave motif on the front. The charcoal box shows a simple drawing of the bottle and a column of icons.

Our standard stock is 350gsm white SBS, which keeps a long panel flat and takes fine print. Brown kraft and other boards can be quoted if you want a plainer look.

Matt or soft touch lamination resists scuffs from handling. Foil on the name and spot UV on a motif are options that read well from a shelf.

Packing and posting boxed sprays

The flat cartons arrive with the side seam glued, ready to open and fill. Box each bottle with the cap firmly on and, for pump sprays, the lock clip or overcap fitted if the bottle has one.

Stand filled cartons upright in an outer. Tall boxes lying flat under weight tend to crush at the top end, right where the cap sits.

What mistakes happen with spray bottle cartons?

• Measuring the bottle body and forgetting the wider trigger head
• Leaving no room above the cap, so the tuck presses the pump
• Using one carton for a cylinder and a Boston round of the same volume
• Placing the logo so low on a tall box that a shelf edge hides it
• Choosing gloss on a box that gets handled at a till, where fingerprints show

Before drawing your proof we hold the dieline up against your figures, which catches nearly all of them while they cost nothing to fix.

How do I order spray bottle boxes?

You get a written figure for your mist cartons, from £0.25 per unit, with any insert or divider itemised. Start by sending us your bottle details through the spray bottle box quote form, then follow these steps.

1. Measure the bottle at its widest point with the cap or head on, or post one to us.
2. Choose a single carton or a pair, and any collar or divider.
3. Pick lamination, foil or spot UV if you want them.
4. Upload your artwork, and our designers fit it to the tall panels free of charge.
5. Check the free proof, looking closely at the height above the cap.
6. Approve, and the run is printed, cut and glued in 4–6 business days.
7. Your flat boxes travel free with tracking and land at your UK address within 2–3 business days.