Supplement bottles are ordered in cc and boxed in inches, and that mismatch causes most of the sizing problems in this category. A 120 cc round packer, a 150 cc and a 175 cc are all common, but cc describes the fill volume, not the glass or resin around it. Change the neck finish from a 38 mm to a 45 mm and the bottle gets wider without getting bigger in cc. So measure.
Four measurements, taken off the filled bottle
- Outside diameter at the widest point. On most packers that is the body, but a flared shoulder or a bulged label panel can beat it.
- Height with the cap fully seated. Use a capped, filled bottle. An unseated cap reads short and a child resistant cap usually reads taller than a plain one.
- Label height and wrap. If the carton has a window or a die cut, the label position matters. If it does not, this is still useful for artwork alignment.
- Weight when full. This decides board grade for the shipper, not for the unit carton.
Then add clearance. A tuck end carton that has to be forced over a bottle will scuff labels on a packing line, and a carton that is loose will let the bottle rattle and the tuck flap pop.
Unit carton, then shipper, in that order
Most supplement brands need two boxes and quote them as if they were one. They are sequential. The unit carton is sized from the bottle. The shipper is sized from the unit carton's external dimensions multiplied by the pack pattern.
| Layer | Sized from | The number that matters |
|---|---|---|
| Unit carton | Bottle diameter and capped height | Internal length x width x depth |
| Inner pack or tray | Carton external size x count | Whether cartons stand or lie |
| Master shipper | Inner pack external size | Gross weight and board grade |
| Pallet pattern | Shipper external footprint | Cases per layer on a 48 x 40 in pallet |
Working in that order stops the common failure where a master case holds eleven cartons with a gap, instead of twelve with none.
Board and print for a unit carton
Unit cartons for supplements are usually folding carton board rather than corrugated, because they are printed, they are not the shipping container, and they need a crisp fold. If the carton is also the shipper for direct to consumer orders, that changes: it now needs corrugated, or it needs to go inside a mailer sized from its outside dimensions.
If your product carries structure or function claims, the panel space for them is part of the sizing conversation. Decide what has to appear on the box before the die is cut, because adding a panel later means a new die.
Ordering, minimum and turnaround
Minimum order is 100 boxes, from about $0.48 per unit at bulk volumes, confirmed on your written quote. Die and plates, design support, US shipping and a digital proof before print are included, so a carton cut to your exact bottle costs no more to tool than a near standard one.
Turnaround runs in three lanes: rush (expedited production with air freight), standard (air) and cost saver (sea), from about 7 business days plus 2 to 5 for delivery, with specialty imported items up to about 12 weeks. Rush adds a premium of about 7 to 25% depending on the job. We run plants in West Chicago and in Guangzhou. To order, see custom supplement boxes.
Measure one filled, capped bottle, decide your case count, and request a quote with both. We will come back with the carton and the shipper together rather than leaving you to reconcile them.
