Pharmaceutical and medical cartons are ordinary folding cartons carrying an unusual amount of responsibility. The structure is not complicated. What matters is that the box has room for the leaflet, a clean surface for variable coding, a closure that shows tampering, and type that stays legible after everything else is fitted in.
What the carton has to accommodate
| Requirement | How it is handled on the carton |
|---|---|
| Product plus leaflet | Add the folded leaflet thickness to the depth before the die is cut, or the carton will bulge and not stack |
| Lot number and expiry | Leave an unvarnished, unlaminated area so inkjet or laser coding takes cleanly |
| Tamper evidence | Glued or perforated end flaps, or a seal area, so opening leaves visible evidence |
| Small mandatory type | Lay out on the dieline first, keep it off scores, avoid reversing tiny type out of solid ink |
| Barcode or data matrix | Flat panel, clear quiet zone, high contrast, never across a fold |
The leaflet is what breaks the fit
Most sizing errors in this category come from measuring the product and forgetting the paperwork. A folded leaflet can add several millimeters of depth, and it does not compress evenly. Measure the product and the leaflet stacked as they will actually be packed, then add clearance. If the leaflet is likely to grow (a new market, a new language), say so at the quote stage so the die is cut with the space already in it.
Coding areas and finishes
Variable data is applied after printing, usually by your own line. Coating and lamination fight that: ink beads on a glossy surface and rubs off. The standard solution is to leave a defined uncoated window on the panel where coding is applied. Tell us where your coder prints and we will keep that area clear on the dieline. It is a small detail that prevents a full pallet of cartons being unusable on a packing line.
What we do and what we do not do
We manufacture the carton: dieline, board, print, finishing and delivery. We do not certify regulatory compliance, we do not approve your artwork against a regulation, and we do not test the finished pack against a standard. Confirm labeling, coding, serialization and testing requirements for your product and market with your own regulatory advisor, then send us the approved artwork and specification and we will build to it exactly. If you need documentation from us about materials used on your job, ask on the quote so it is agreed in writing before production.
Batch sizes, price and scheduling
The minimum is 100 boxes, which suits clinical batches, samples and small market launches as well as commercial runs. Expect from about $0.48 per unit at bulk volumes, with the exact figure set on your written quote. The cutting die, print plates, design support and US shipping are included, and a digital proof is issued before print so your regulatory reviewer can sign off the actual layout rather than a description of it.
Standard production starts from about 7 business days, and delivery takes a further 2 to 5. Rush uses expedited production with air freight and carries a premium of about 7 to 25% depending on the job. Cost saver ships by sea at the lowest cost and the longest lead time. Confirm your lane in writing if a batch release date depends on it.
Send the specification
Put your carton dimensions, leaflet size, coding area and quantity into the quote form. Related formats are covered on custom medicine boxes and supplement boxes.
