A mascara carton is one of the most awkward shapes in cosmetics packaging: narrow, tall, and holding a single item that has to stand up rather than lie down. The sizing itself is simple. The board choice is where most of the mistakes happen, because a tall thin panel in light board bows and the carton looks cheap on shelf.
Measuring the tube
Take three numbers, all with the cap on and closed.
- Widest diameter. On many tubes this is not the barrel. It is the cap, or the collar where the cap meets the tube. Measure with calipers across the fattest point and rotate the tube, because moulded tubes are rarely perfectly round.
- Overall height. Base to the crown of the cap. If the cap has a domed top, measure to the top of the dome.
- Base diameter. This decides whether the tube will stand inside the carton or lean against a wall.
Add roughly 1/16 to 1/8 in of clearance in the footprint so the tube drops in on a filling line rather than being pushed. Add a little more in the height if a leaflet sits under or over the product.
Board caliper, which is the real decision
Folding carton board is quoted in points. One point is one thousandth of an inch. These are the published industry calipers, offered as a reference range rather than an iBox stock list, and the finished caliper is confirmed on your quote.
| Caliper | In inches | In millimetres |
|---|---|---|
| 14 pt | 0.014 in | About 0.36 mm |
| 16 pt | 0.016 in | About 0.41 mm |
| 18 pt | 0.018 in | About 0.46 mm |
| 20 pt | 0.020 in | About 0.51 mm |
| 24 pt | 0.024 in | About 0.61 mm |
The taller and narrower the carton, the more a heavier caliper earns its cost. It also has a dimensional effect: on a carton with a 1 in cavity, moving from 14 pt to 24 pt adds visible thickness to every wall, which is exactly why the internal versus external question is not pedantry.
Grain direction
Paperboard has a grain, and it folds cleanly along the grain and roughly across it. On a tall narrow carton you generally want the grain running vertically so the long panels stay straight, and the cross scores hit the grain squarely. Your supplier decides this when the dieline is laid out, but it is worth naming on the spec if the carton is unusually tall, because a bowed front panel on a shelf is the most common complaint about this format.
Opening style and shelf behaviour
A straight tuck end keeps the front panel unbroken, which suits a printed face. A reverse tuck is cheaper to nest on the sheet and shows a flap edge on the front. Tuck with a dust flap lock resists being shaken open in transit. For a set that includes a liner or a primer, a tray and sleeve gives a better reveal but adds two components and a cost line. Decide it before artwork, because the dieline changes the printable area.
Minimum order, price and lead time
Mascara cartons start at 100 units. Price runs from about $0.48 per unit at bulk volumes, confirmed on your written quote. The cutting die, the printing plates, design support, US shipping and a digital proof are included, so a cavity cut to your exact tube costs no more to tool than a near standard one. Turnaround is stated per product in three lanes, rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days of production plus 2 to 5 days for delivery. Rush carries a premium of roughly 7 to 25% depending on the job. Production runs from West Chicago in the US and Guangzhou in China.
Send the capped tube measurements and the caliper you have in mind and we will send back a dieline and a price. Start at request a quote, or order from the custom mascara boxes page. The related spec sheet on eyeliner boxes covers the even narrower end of the same family.
