Truffle packaging is almost entirely an insert design problem. Once the cavity grid is settled, the carton dimension follows automatically and the remaining decisions are about material and finish. So start with the grid.
Fix the grid
Common retail counts are 4, 6, 9, 12, 16 and 24 pieces, and each maps to a different grid: a 12 piece box can be 3 by 4 or 2 by 6, and those two produce very different shelf shapes and very different gift presentations. Decide the count and the arrangement together, not separately.
- Measure a production truffle at its widest point. Hand-rolled and hand-dipped pieces are larger than the mould specification.
- Add the cavity wall so pieces do not touch. Touching truffles scuff each other and pick up each other's coating.
- Multiply the cavity pitch by the grid to get the internal footprint.
- Take depth from the tallest piece, plus the insert floor thickness, plus a small clearance so the lid does not press on the decoration.
Insert options
| Insert | Character | Best for |
|---|---|---|
| Vacuum formed plastic tray | Crisp cavities, cleanable, holds pieces precisely | Volume retail assortments |
| Moulded pulp tray | Paper-based, softer cavity edges | Brands prioritising a single-material story |
| Die cut board grid | Ships flat, assembled at packing | Lower price points and seasonal runs |
| Individual paper cases in a tray | Traditional, forgiving of size variation | Hand-made and artisan ranges |
The last option deserves attention if your pieces vary in size. Paper cases absorb variation that a moulded cavity cannot, which is why traditional chocolatiers still use them.
Carton construction
Rigid two piece boxes dominate the gift end of the category because the weight in the hand does a lot of the selling, and because a rigid lid protects a soft product better than a tucked flap. Folding cartons ship flat and cost less per unit, which matters on seasonal volume. A window shows the assortment and adds a film patch and a step, and it also exposes the chocolate to light, which matters for a product that is already temperature sensitive.
Temperature is a logistics question
Packaging slows temperature change, it does not control it. If your product ships in summer or to warm markets, the answer is in your cold chain and your shipping calendar, not in the carton. Be honest about that internally, and do not print claims about heat tolerance that the pack cannot deliver.
Ordering
Minimum order is 100 boxes, and pricing runs from about $0.48 per unit at bulk volumes, confirmed on your written quote. The die and plates, design support, US shipping and a digital proof before anything prints are included, which is why a box cut around your own cavity grid tools no differently from a near-standard size. Turnaround is stated per product in three lanes: rush with expedited production plus air freight, standard by air, cost saver by sea, from about 7 business days, plus 2 to 5 for delivery. Specialty imported items can run up to about 12 weeks. Production is in West Chicago and in Guangzhou.
This page is the specification guide. Truffle boxes is the product page and the place to order, and chocolate boxes covers the wider category. Send your piece diameter, count and preferred grid to request a quote.
