Battery packaging has to do three things at once: hold a dense product securely, present a count and a specification clearly enough that a shopper picks the right one, and carry the marks that regulation and carriers require. The third of those is the one that decides the layout, so start there.
Leave the panel space first
Battery packs are small and the mandatory content is not. Chemistry, voltage, capacity, cell type, manufacturer identification, disposal and recycling symbols, and for lithium cells the transport marks and any handling labels all compete for the same surface as your brand. Draw those into the dieline before the design is finalised, with the sizes your regulator and your carrier require.
To be explicit: iBox Factory prints the artwork you supply. We do not certify that a pack meets any transport, dangerous goods or product safety requirement. Lithium cell shipments in particular carry obligations that sit with you and your carrier, and they must be confirmed independently before the proof is approved.
Pack formats
| Format | Suits | Watch for |
|---|---|---|
| Hang tab carton | Peg display in hardware and convenience retail | Reinforce the hole, the pack is heavy for its footprint |
| Window carton | Showing cell type and count directly | The aperture removes board, keep a solid frame |
| Slide or tuck sleeve | Multipacks and repeat-purchase formats | Needs an insert or the cells shift and rattle |
| Tray with printed outer | Larger cells and battery packs | Tray must locate each cell so terminals do not contact |
| Counter display outer | Impulse placement at the till | Base carries real weight, specify board accordingly |
Structure for a dense product
- Board grade follows weight. A pack of cells weighs more than its size suggests, and the base and the hang tab take the load.
- Inserts stop movement. Cells that slide inside a carton rattle, wear the print from the inside, and can bring terminals into contact. A die cut tray or partition fixes it.
- Corners fail first. On peg display, packs get knocked repeatedly. A rounded corner or a slightly heavier caliper at the top of the pack survives longer than a decorative flourish.
- Tamper visibility. Retailers often want to see whether a pack has been opened. Decide on a closure that shows it.
Print and shelf legibility
Battery shoppers scan for a size and a count, in that order, usually in a hurry. Put both on the front panel at a size readable at arm's length, and repeat the size on the top edge so the pack is identifiable when it hangs behind another. Save the brand story for the back panel where there is room for it.
Ordering a battery pack run
The minimum order is 100 boxes. Pricing starts from about $0.48 per unit at bulk volumes and is confirmed on your written quote. Die, plates, dieline design support, free US shipping and a digital proof before print are included. Production runs from about 7 business days, plus 2 to 5 for delivery, and three lanes are quoted per product: rush (expedited production plus air freight, about 7 to 25% premium depending on the job), standard (air) and cost saver (sea). Specialty imported items can run up to about 12 weeks.
Send your cell specification
Send the cell dimensions, the pack count, the loaded weight and your required marks to /quote/. For related categories, see custom electronic boxes and hanging boxes.
