Hang tab boxes are sized twice: once for the product, and once for the peg. The second one is where orders go wrong, because a box that is perfect in every other respect is useless if it will not sit on the retailer's hook or if it tears off it by the end of the day.
The hang styles and their dimensions
| Style | Typical opening | Notes |
|---|---|---|
| Round hole | About 1/4 to 5/16 in diameter | The simplest and cheapest, die cut into an extended tab |
| Delta or teardrop | Round hole with a tapered slot below | Slides onto the hook more easily and spreads load a little wider |
| Euro slot | Round top with a wider slot beneath it | Common in European retail, so confirm the exact shape against the retailer's own packaging spec |
| Adhesive hang tab | Applied after packing | No change to the die, useful when only some stock is merchandised on pegs |
Retailers frequently publish their own packaging specification with a required hole shape and position. If you are selling into one, ask for it before the die is cut. It is a cheap question and an expensive assumption.
Where the hole goes
Center it on the width. Then check where the weight sits: if the contents are heavier at one end, the box will hang at an angle no matter where the hole is, and the fix is an insert that keeps the load centered rather than moving the hole. Keep at least about a quarter of an inch of board above the hole. That strip carries the entire weight of the pack, and it is the first thing to tear when a shopper pulls a unit off a full peg.
Reinforcement, and when you need it
A single thickness of folding board is fine for light contents. As soon as the pack has real weight, the tab needs help. The options, cheapest first: fold the tab back on itself so the hole passes through two thicknesses, step up the board caliper, or apply a reinforced adhesive tab over the punched hole. Test with the heaviest version of your packed product, not an empty sample, and test by pulling it off a hook rather than by hanging it still.
Pegboard reality
Standard pegboard has holes on a one inch grid, and the peg hooks that go into it project a fixed distance from the wall. That has two consequences for your box. The depth of your pack has to be sensible for a hook that may only be a few inches long, and units hanging behind each other on the same hook have to be consistent in depth so the row does not run out of hook. If your box is deep, a shelf placement may serve you better than a peg.
Print around the tab
The tab is often the only part of the pack visible when units hang behind one another, so it is worth putting the brand mark on it rather than leaving it blank. Keep artwork clear of the punched hole itself, and avoid running critical type into the area that gets folded if you are using a folded reinforcement.
Adding a tab to an existing box
Adding a hang tab is a die change, and the die is included in your quote. The minimum is 100 boxes. Bulk pricing starts from about $0.48 per unit, confirmed on your written quote. Standard timing starts from about 7 business days in production and 2 to 5 for delivery; rush and cost saver are quoted against the specific job.
Get the tab specced
Send your packed weight, the retailer specification if you have one, and quantity to the quote form. For the wider format see hanging boxes, and for shelf and peg merchandising see custom packaging for retail shelf.
