This page is the guide. To order a standard construction, go to handle boxes. If you have had handles tear, or you are packing something heavier than a gift, the three decisions below are the ones that matter.
Decision one: which handle
| Handle type | How the load is carried | Best suited to |
|---|---|---|
| Die cut hole | Directly by the board around the cut out | Light contents, lowest cost, nothing to assemble |
| Die cut with a folded reinforcement flap | Doubled board at the grip | Medium weight, still a single material |
| Rope or cord through eyelets | The eyelet spreads load into the panel | Retail carriers and heavier gifting |
| Ribbon handle | Knotted or glued behind the panel | Presentation pieces where the handle is decorative |
| Integrated gable or carrier top | The structure itself forms the grip | Food carriers and meal boxes |
Decision two: board weight for the actual load
Weigh what you are putting in the box, then be honest about how it will be carried: swinging from one hand, or held from underneath. A die cut handle in a light folding board is fine for a scarf and will tear with a pair of ceramic mugs in it. Two things fix it. Heavier board or corrugated instead of folding carton, and a reinforced grip so the load is not carried by a single thickness of paper. Between those, the reinforcement usually costs less than upgrading the whole box.
One detail that prevents most tearing: the corners of a die cut handle should be radiused, not square. A sharp internal corner is where a tear starts and then runs across the panel. If you are supplying your own artwork on a dieline, do not redraw the handle as a rectangle.
Decision three: where the handle sits
Size the box around the contents first and the handle second, then check two things. The handle has to sit high enough that the box hangs level when carried, which usually means centered on the width with the cut out near the top edge. And there has to be enough material above the cut out to take the strain: if the hole is too close to the top edge, the strip left above it is what tears. If the contents are heavy on one side, the box will hang crooked no matter where the handle is, so an insert that keeps the load centered is part of the handle design.
Print and finish
Handles interrupt artwork. Keep logos and important type away from the cut out, since anything that runs into a handle gets a thumb over it every time the box is carried. On laminated boxes, check that the laminate is trimmed cleanly at the handle edge, since a peeling laminate at the grip is the first thing a customer notices. Design support is included, so send the artwork and we will place it on the blank around the handle.
What handles add to the price
Handle box runs start at 100 boxes. Pricing starts from about $0.48 per unit at bulk volumes, confirmed on your written quote, with rope or ribbon handles adding a component and a hand assembly step compared to a die cut hole. The cutting die, plates, design support and US shipping are included, and you approve a digital proof before print.
The standard lane starts from about 7 business days in production, with 2 to 5 days on top for delivery. Choose rush for expedited production and air freight, at about 7 to 25% more depending on the job, or cost saver for sea freight at the lowest cost. Handles with added components are more likely to sit in the specialty lane, which can run up to about 12 weeks, so confirm the lane if a date is fixed.
Order or ask
Buy the standard construction on the handle boxes page, or send contents, weight and quantity to the quote form for a custom size. If the carrier is for food service, gable box dimensions covers the integrated carrier alternative.
