To order, see contact lens boxes. This guide covers what to work out first: the internal size, the closure, the print, and the details that make a small carton run cleanly.
Measure the blister array, not the lens
- Assemble the exact strip configuration you sell: the number of blisters per strip and the number of strips per carton.
- Measure the assembled stack at its widest and tallest, with the foil lidding on. Foil edges lift slightly, and on a small carton that is enough to matter.
- Add the leaflet, folded as it will be folded, and measure the combined stack again.
- Add clearance so the carton loads easily on a line rather than being forced by hand.
Formats and what each one needs
| Format | What sets the internal size | Carton note |
|---|---|---|
| Blister strips, daily lenses | Strip length and the number of strips stacked | Usually a straight or reverse tuck end, leaflet on top |
| Vials, monthly lenses | Vial height and the tray or fitment holding them upright | Taller carton, fitment stops vials tipping |
| Multipack or value pack | The count of unit cartons inside | Outer carton sized from the finished unit carton |
| Sample or trial pack | A short strip plus a leaflet | Small carton, close to the practical folding limits |
Tamper evidence and closure
Decide the closure with the dieline. A glued end carton opens by tearing and shows it has been opened. A tuck end with a tear strip does the same job with a different look. A plain tuck end is the cheapest and shows nothing. Whichever you choose changes the flap geometry, so it needs to be on the brief rather than raised at proof stage.
Print on a small panel
Contact lens cartons carry a lot of mandatory information on a small surface: parameters, batch, expiry, and whatever your market requires. Two practical points. First, leave a clear, unvarnished area if batch and expiry are overprinted on your line, because ink does not key reliably onto a laminated surface. Second, keep the smallest type in a simple face at a size that survives the print process, and keep it away from folds and glue areas. What has to appear on the pack, and in what form, is set by the rules of the markets you sell into. We print the panel you supply and we do not assess whether it meets a regulatory requirement, so have it reviewed before plates are made.
Ordering
The minimum is 100 cartons. Pricing starts from about $0.48 per unit at bulk volumes and is confirmed on your written quote. Turnaround is quoted per product across three lanes: rush, which is expedited production plus air freight, standard on air, and cost saver on sea, from about 7 business days in production plus 2 to 5 days for delivery, with specialty imported constructions running up to about 12 weeks. The cutting die, the plates, design support, US shipping and a digital proof are included, which is why a carton sized exactly to your blister array costs no more to tool than a near standard one.
To order, see contact lens boxes. If overprinting and artwork are your open questions, what bleed is in packaging artwork covers how to supply files. Send your blister measurements with a quote request.
