Eyeshadow packaging is judged on colour fidelity and on whether the pressed product survives the journey. Both are specification problems you can solve before the first sample. This guide covers how to specify the carton; the custom eyeshadow boxes page is where the order is placed.
Sizing: pans, compacts and palettes
Pan sizes in cosmetics have largely standardised, with 26 mm as the common single pan diameter and 36 mm used for larger pans. Those numbers describe the metal pan, not the plastic compact around it, so the carton is sized from the compact or the palette rather than from the pan. Measure:
- The closed compact or palette at its widest point, in both plan directions.
- The closed height including the hinge, the magnet closure and any raised branding on the lid.
- The mirror, if fitted, which is usually already inside the measured height but adds weight that the carton has to hold.
Add about 1/16 to 1/8 in of clearance per side for a snug retail carton. A palette is heavier than it looks, so allow for that at the base.
Protecting pressed powder
Pressed shadow cracks from vibration and from flexing of the pan, not usually from a single impact. That means the enemy is free movement. A carton that grips the palette, or a die cut tray that holds it with no play, protects better than a loose carton with a cushion in it. For ecommerce, add an outer shipper rather than making the retail carton thicker, and keep palettes flat rather than on edge.
Printing an accurate shade
| Design goal | Specify | Why |
|---|---|---|
| Match the actual shadow shade on the carton | Spot ink from an ink matching system | A process build drifts run to run, which is visible against the product |
| Photographic swatches of the whole palette | CMYK process on white cardstock | Photography needs process printing and a bright base |
| Metallic or duochrome effect on the pack | Foil stamping or metallic stock | Process inks cannot reproduce metallic effects |
| Deep matte black or a rich solid | Spot ink plus matte lamination | Heavy solids print more evenly as a spot colour |
| Show the real shades | Die cut window with a film patch | No print can match a pressed powder exactly |
Plates are included, so adding a spot ink for a brand shade is a print quality decision rather than a tooling cost.
Construction choices
Single shadows usually run as reverse or straight tuck end cartons. Palettes tend to sit in a tuck top carton, a two piece rigid box, or a sleeve over a tray. Rigid gives a keepsake feel for a premium palette and takes foil and embossing beautifully. A sleeve and tray lets you run several colourways from one structural die by changing only the printed sleeve, which is the cheapest way to launch a range.
Materials and finishes
Standard white cardstock is the default for colour accuracy. Foil metallic, holographic, textured and coloured stocks all exist for differentiation, and rigid press board is available for premium palettes. Finishing includes gloss and matte lamination, spot UV, foil stamping and embossing.
Ordering
The minimum is 100 boxes and pricing starts from about $0.48 per unit at bulk volumes, confirmed on your written quote, with the die, plates, design support, US shipping and a digital proof included. Turnaround is quoted per job in three lanes, rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days, plus 2 to 5 for delivery.
Order on the custom eyeshadow boxes page, or send compact measurements and artwork to the quote form. Related: cosmetic box dimensions.
