Everything you need to know before ordering custom chocolate boxes, from styles and sizes to board, printing and sustainability.
This guide is for chocolatiers, lolly shops, confectioners and gift retailers looking at custom chocolate boxes. It covers what matters most before you order, with practical examples from Australian food businesses.
What are custom chocolate boxes?
Custom chocolate boxes are food-grade boxes made to your size, structure and artwork instead of picked from a generic range. They are used for assorted chocolates, pralines, gift boxes and corporate gifts, and they are a staple for chocolatiers, lolly shops, confectioners and gift retailers across Australia.
Moulded trays and rigid walls protect tempered chocolate from scuffs and fingerprints. That practical detail matters because a box that fails in transit costs you the food, the customer's goodwill and often a refund. A well-made box does the opposite: it protects the product, carries your brand into homes and offices, and gives people a reason to remember where the food came from.
You can see standard sizes and options on our Chocolate Boxes page, or browse the wider range of chocolate & confectionery boxes.
Popular uses for chocolate boxes
Most orders for chocolate boxes come from businesses packing assorted chocolates and pralines, but the same box often ends up doing several jobs across a menu or product range.
- Assorted chocolates: repeat customers notice when the packaging looks consistent every time.
- Pralines: the food often travels further than you'd expect, so strength counts.
- Gift boxes: a box that photographs well brings free exposure on social media.
- Corporate gifts: the box has to hold its shape from the counter to the customer's table.
If your range covers more than one of these, it is usually cheaper to settle on two or three standard sizes and print them all with the same artwork than to order a different design for every item.
Box styles for chocolate boxes
The structure of the box decides how fast it folds, how well it protects the food and how it looks when opened. These are the styles we make most often for chocolate boxes:
- Rigid lid and base: Thick wrapped board gives a solid, premium box that customers tend to keep.
- Slide drawer: A tray slides out of an outer sleeve like a matchbox, which makes opening part of the experience.
- Window box: A window shows the product and lets it sell itself on the counter or shelf.
If none of these fits, we can combine features, for example adding a window to a tuck box or an insert to a lid-and-base box. Your dieline is drawn around the food, so the finished box fits properly.
Standard sizes for chocolate boxes
These are the sizes customers ask for most often. They are a good starting point, but every box can be made to your exact dimensions.
| Popular size | Common use |
|---|---|
| 100 x 100 x 30 mm | assorted chocolates |
| 200 x 150 x 35 mm | pralines |
| 250 x 250 x 40 mm | gift boxes |
| Custom | Any size to suit your product |
As a rule, allow 5 to 10 mm of clearance on each side of the food and more on top if it has icing, toppings or a domed shape. Too much space lets food slide around; too little crushes it or smears it on the lid.
Board and material options
The right board depends on the weight of the food, how far it travels and the look you want. For chocolate boxes the usual options are:
- Rigid greyboard: Thick board, usually 1.5 to 2.5 mm, wrapped in printed paper. It is used for premium gift boxes that customers keep and reuse long after the food is gone.
- SBS paperboard: Solid bleached sulphate board gives a bright white surface for sharp, full-colour print. It is the usual choice for retail cartons and bakery boxes, and is commonly specified between 300 and 400 gsm depending on the weight of the food.
- Inserts and trays: Card, board or moulded pulp inserts hold individual pieces in place. Moulded pulp and folded card are the common alternatives to plastic trays.
The main risk to plan for with this type of packaging is heat, humidity and scuffing of glossy surfaces. Choose the board and any inside coating with that in mind, not just the print.
Printing options for chocolate boxes
Most chocolate boxes are printed in one of three ways, and the right one depends on your quantity and artwork.
- Offset CMYK: sharp full-colour print for photos, gradients and detailed designs. Best value on larger runs.
- Spot colours (Pantone): exact brand colours that stay consistent between orders. Worth it if colour matching matters to you.
- Digital print: no plates, so it suits short runs, test designs and seasonal versions.
On kraft board, bold one- or two-colour designs usually look better than full photos, because the brown base changes how colours appear. Our CMYK vs Pantone guide explains the difference in more detail.
Eco-friendly chocolate boxes
Paperboard chocolate boxes are one of the easier food packaging items to make sustainable, because the main material is widely recycled in Australia when it is clean.
- Choose kraft or recycled-content board where the look suits your brand.
- Use a film-free window or no window at all, so the box stays a single material.
- Ask for water-based barrier coatings rather than plastic laminates where grease resistance is needed.
- If you want compostable packaging, ask for certification to AS 4736 (industrial) or AS 5810 (home composting).
- Add clear disposal instructions, such as the Australasian Recycling Label, so customers know what to do with the box.
Most states have also phased out many single-use plastic food items, so paper-based boxes help keep you ahead of the rules. Check your state's current list, as it changes.
The ordering process, step by step
Ordering chocolate boxes is simple, and you see a proof before anything is printed.
- Request a quote with your size, quantity and any style ideas using our quote form.
- Get a dieline: a flat template of your box showing folds, cuts and print areas.
- Add artwork: send your own, or ask our team to lay out your logo and details.
- Approve the proof: check spelling, colours and positions carefully.
- Production: printing, finishing, cutting and gluing, typically 10–15 business days.
- Delivery: boxes arrive flat-packed, ready to fold.
Not sure how a dieline works? Read how to read a packaging dieline.
Frequently asked questions about chocolate boxes
Do you make chocolate boxes in custom sizes?
Every box is made to order, so any size is possible. We draw a dieline around your measurements.
What is the minimum order for custom chocolate boxes?
Orders start from 100 units for most styles. Larger runs lower the price per box.
Are chocolate boxes recyclable?
Paperboard boxes are widely recyclable in Australia when clean. Heavy food waste or plastic laminates can make recycling harder.
Can I order different designs in one run?
Often, yes, if they share the same size and board. Ask us about splitting artwork across one order.
Ready to get started?
The best chocolate boxes are the ones that fit the food, suit the way your team works and look like they belong to your brand. Measure carefully, choose board for the conditions the box will face, and keep the design clear and consistent.
When you're ready, see the full specification on our Chocolate Boxes page or request a free quote. We'll send a dieline and price for your exact size.
Get a price for your boxes
Send your size and quantity. We reply with a dieline and quote.