A thermometer is a small device that ships with a disproportionate amount of paper. Regulatory text, multi-language instructions, a warranty card and a calibration note all have to go somewhere, and on plenty of these cartons the folded leaflet is physically larger than the thermometer. That is why the leaflet is the first thing to measure.
Fold sizes for the leaflet
Paper folding is one of the few genuinely standard things in packaging, because both the US and the ISO sheet systems halve predictably. These are published sheet standards, useful as planning figures.
| Sheet | Flat | Folded once | Folded twice |
|---|---|---|---|
| US letter | 8.5 x 11 in | 5.5 x 8.5 in | 4.25 x 5.5 in |
| ISO A4 | 210 x 297 mm | A5, 148 x 210 mm | A6, 105 x 148 mm |
A cross fold or a roll fold gives you other footprints, and a thick multi-language leaflet folded several times builds real depth. Give the print buyer the finished folded size, then size the carton around the larger of the leaflet and the device.
The longest rigid part sets the length
For a digital stick thermometer, the probe and the body are one piece and the overall length is straightforward. For a probe thermometer with a lead, the probe is rigid and the lead is not, so the carton has to clear the probe laid flat while the lead coils around it. For an infrared or forehead unit, the body is the constraint and the shape is awkward rather than long. Measure the single longest rigid item, then check nothing else in the pack exceeds it.
What else is in the pack
- Probe covers. Usually supplied in a strip or a small bag, and the bag is wider than the covers.
- Battery. Loose, taped, or fitted with a pull tab. A loose coin cell needs retaining or it moves around the carton.
- Storage case or sleeve. If one is included it becomes the item to measure, not the device.
- Insert card or tray. Adds its own caliper on every axis it touches.
Hang tab, blister or plain carton
If the pack sells off a peg, you need a euro hole or a hang tab at the top, and that occupies height above the product cavity with no product in it. That area also takes the entire weight of the pack at the hook, so it wants board that will not tear, or a reinforced tab. If the pack sells off a shelf face on, you can use that height for branding instead. Deciding hang against shelf before you size the carton stops you redesigning the die later. Our explainer on folding cartons covers which closures suit a pegged pack.
Ordering, minimums and lanes
Minimum order is 100 boxes. Pricing starts from about $0.48 per unit at bulk volumes and is confirmed on your written quote. Die, plates, design support, US shipping and a digital proof are included. Three lanes are available, rush with expedited production and air freight, standard on air, and cost saver by sea, from about 7 business days, plus 2 to 5 for delivery. We produce in West Chicago and Guangzhou.
Send the folded leaflet size and the length of the longest rigid part with your quote request, and say whether the pack hangs. If the device is electronic and ships as a parcel, how to package electronics for shipping covers what the outer pack needs to do.
