Vape Packaging

Custom Vape Packaging UK

Create custom vape packaging around the exact dimensions of your cartridges, pods, refill bottles, reusable devices and starter kits.

All Custom Packaging produces printed vape boxes for lawful products sold by manufacturers, importers, private-label businesses and specialist retailers across the UK.

Vape products are often compact, high-value and made from several easily damaged components. The outer box must keep those components organised while reserving sufficient room for product identification, warnings, instructions and other information required for the intended market.

We develop the dieline around your actual product rather than relying on a generic stock carton. The structure can include a fitted card or foam insert, retail hang tab, window, lock-bottom base or separate compartments for devices, pods, cables and instructions.

Why Vape Brands Choose All Custom Packaging

Vape packaging needs to balance product fit, regulatory information and brand presentation.

A cartridge that moves inside an oversized carton can rattle, rub against the board and arrive with scuffed surfaces. Loose components inside a starter kit can also collide during handling or appear poorly organised when the box is opened.

Before recommending a structure, we consider:

• Product length, width and height
• Cartridge, pod or bottle capacity
• Total packed weight
• Number of components
• Required warnings and product information
• Insert or divider requirements
• Retail shelf or hanging display
• E-commerce delivery
• Opening and closure style
• Exterior and interior printing
• Current packaging restrictions

All Custom Packaging accepts orders from 100 units per design, with no setup fees, free design support and a free 3D mockup. Production normally takes 6 to 8 business days after artwork and sample approval, followed by free delivery throughout the UK.

You also approve a video of the physical sample before the complete run is produced. This allows you to review the product fit, insert, closure, warning panels, print position and overall presentation.

What Vape Packaging We Make

Our vape cartridge boxes are slim retail cartons developed around the dimensions of the cartridge and any protective container used around it.

They can be produced for suitable cartridge sizes such as:

• 0.5ml cartridges
• 1ml cartridges
• Replacement pods
• Prefilled cartridges
• Empty hardware cartridges
• Specialist lawful formats

Available structural features include:

• Straight tuck ends
• Reverse tuck ends
• Lock-bottom bases
• Hang tabs
• Clear product windows
• Die-cut card inserts
• Foam supports
• Printed instruction panels
• Batch and barcode areas

Explore 1 Gram Vape Cartridge Packaging for compact cartridge formats requiring branded outer cartons.

The product owner must confirm that the cartridge, liquid and associated claims are lawful for the intended UK market. Supplying packaging does not establish the legality or regulatory status of the product inside.

Empty Vape Cartridge Boxes

Our Empty Vape Cartridge Boxes are supplied without the cartridge or product inside. They can be used by approved businesses for their own compliant filling, labelling and kitting processes.

Empty boxes can include:

• Blank batch areas
• Variable product labels
• Flavour or variant panels
• Cartridge-size identification
• Barcodes
• QR codes
• Instructions
• Warning areas
• Tamper seals
• Retail hang tabs

Plain or minimally printed versions are also available for businesses that apply their own labels after filling.

Refillable Pod Packaging

Custom pod boxes can be created for refillable pods, replacement pods and compatible components.

The structure can hold:

• Single replacement pods
• Multi-pod packs
• Refillable cartridges
• Coils
• Mouthpieces
• Small accessories
• Instructions or safety leaflets

Die-cut slots can keep each pod upright and separated. Where several pods are packed together, internal dividers can prevent them from rubbing or moving during handling.

The box should clearly identify the compatible reusable device so customers and retailers can distinguish between similar components.

Reusable Vape Device Boxes

Reusable vape-device packaging can be developed for rechargeable and refillable systems that meet the applicable UK rules.

Device boxes may hold:

• Rechargeable vape devices
• Refillable pod systems
• Mods
• Tanks
• Replacement coils
• Charging cables
• Mouthpieces
• User instructions
• Warranty information

A fitted insert can create a separate position for each component. This improves presentation and reduces movement during storage and distribution.

Since 1 June 2025, it has been illegal throughout the UK to sell, offer for sale or supply single-use vapes, whether or not they contain nicotine. Packaging for the UK market should therefore be developed for lawful reusable products rather than banned disposable formats.

Vape Starter-Kit Boxes

Starter kits normally combine a device with several accessories, so the internal layout is particularly important.

A kit box can include compartments for:

• Reusable device
• Refillable tank or pod
• Replacement coil
• Charging cable
• Mouthpiece
• Instruction leaflet
• Warranty card
• Approved accessories

Starter kits can use folding cartonboard for lighter products or rigid board for premium presentation. Corrugated outer protection may be added when the kit will be sent directly through a courier network.

A kit must not combine an otherwise compliant product with a non-compliant tank, accessory or component.

E-Liquid Boxes

E-liquid cartons can be produced around the bottle diameter, cap and total height.

For nicotine-containing refill containers sold to consumers, current UK rules restrict the container volume to 10ml and nicotine strength to a maximum of 20mg/ml. Electronic-cigarette tanks are restricted to 2ml. Nicotine-containing products or their packaging must also be child-resistant and tamper-evident.

E-liquid boxes can include space for:

• Product and flavour name
• Nicotine strength
• Liquid volume
• Ingredients
• Batch number
• Warning text
• Storage instructions
• Business contact details
• Barcode
• Required symbols
• Information leaflet
• Duty or coding areas where applicable

The carton should be measured around the complete closed bottle, including the cap and any tamper-evident band.

Shortfill and Nicotine-Free E-Liquid Boxes

Larger bottles of nicotine-free e-liquid may fall outside certain nicotine-product provisions of the Tobacco and Related Products Regulations, but they remain subject to other product-safety, chemical, packaging and labelling requirements.

Shortfill boxes can be created for:

• 50ml bottles
• 60ml bottles
• 100ml bottles
• 120ml bottles
• Multi-bottle sets
• Nicotine-free products
• Related lawful refill products

The exact legal position depends on the formulation, presentation, intended use and market. Artwork should be approved by the responsible business or regulatory adviser before printing.

Materials and Inserts

Component	Available Options
White SBS cartonboard	Smooth white board for cartridge, pod, bottle and lightweight device cartons
Rigid greyboard	Thick wrapped construction for premium reusable-device kits and presentation boxes
Natural kraft board	Brown board for restrained branding and suitable lawful product ranges
Corrugated board	Additional protection for shipping cartons and heavier multi-component kits
Card inserts	Die-cut trays and compartments that organise cartridges, pods, bottles and accessories
Foam inserts	Closely fitted support for fragile, high-value or heavier components
Windows	Clear PET or another suitable film where product visibility is required
Extras	Hang tabs, tuck closures, lock-bottom bases, tamper seals and printed interior panels

SBS Cartonboard for Retail Vape Boxes

White SBS cartonboard is suitable for many cartridge, pod and e-liquid cartons.

It provides:

• A smooth printing surface
• Clear reproduction of small text
• Full-colour artwork
• Efficient flat storage
• Quick assembly
• Tuck and lock-bottom structures
• Hang-tab options
• Die-cut windows

Small regulatory text must remain clear after printing, cutting and folding. The dieline should therefore reserve sufficient quiet space around warnings, ingredients and other required information.

Rigid Vape Kit Boxes

Rigid greyboard can be used for premium rechargeable devices, specialist hardware and multi-component starter kits.

Available structures include:

• Magnetic closures
• Lift-off lids
• Drawer-style openings
• Hinged lids
• Ribbon pulls
• Printed inner walls
• Multi-level inserts

Rigid packaging is heavier and uses more material than a folding carton. It is most appropriate where the product value and presentation justify the additional construction.

A rigid presentation box may still require a protective corrugated outer carton for e-commerce delivery.

Kraft Vape Boxes

Kraft board can provide a natural brown appearance for suitable lawful product ranges.

It works well with:

• Black printing
• White ink
• Simple logos
• One- or two-colour artwork
• Product labels
• Embossed details

A brown kraft appearance does not automatically make the finished packaging recyclable or environmentally preferable. Windows, laminations, foil, adhesives and inserts can affect the disposal route.

Environmental statements should be based on the complete finished box rather than the appearance of the board alone.

Inserts Designed Around Vape Components

A fitted insert is especially valuable for cartridges, pods, glass bottles and device kits.

It can:

• Hold components in the intended position
• Reduce rattling
• Prevent products from rubbing together
• Separate cables and accessories
• Improve presentation when opened
• Keep warning leaflets organised
• Support delicate cartridges or bottles
• Make missing components easier to identify

The insert is designed around the exact component list rather than only the outside dimensions of the main device.

When requesting a quotation, provide physical samples or accurate dimensions for every item included in the kit.

Die-Cut Card Inserts

Card inserts create a clean paper-based presentation and can be printed or colour-matched to the outer box.

They are suitable for:

• Cartridges
• Pods
• E-liquid bottles
• Coils
• Small accessories
• Lightweight devices

Foam Inserts

Foam inserts provide firmer support and cushioning for:

• Premium devices
• Glass components
• Heavy batteries
• Electronics
• Multi-component kits
• Products requiring a precise fit

The suitability and disposal route of foam should be considered when preparing environmental claims.

Retail Hang Tabs

Hang tabs can be added to lightweight cartridge, pod and accessory cartons for display on retail hooks where permitted by current rules and retailer policies.

The hang tab should be:

• Centred above the loaded product
• Strong enough for the packed weight
• Positioned away from required warning text
• Tested on the physical sample
• Sized for the intended retail hook

The front panel must remain stable and readable while the box is hanging.

Clear Vape Packaging Windows

A die-cut window can show the device, cartridge or bottle without opening the box.

Windows can be added to suitable structures using clear PET or another specified transparent film.

The design should ensure that the window:

• Does not weaken the main structural panels
• Does not cover required information
• Does not expose sensitive components
• Leaves enough space for warnings
• Remains appropriate under current vape-packaging rules

Window materials may need to be separated from the paperboard before recycling.

UK Vape Packaging and Labelling Space

Custom packaging can reserve panels for the wording and symbols supplied by the responsible business. However, the box manufacturer does not determine whether a product is compliant.

Under current TRPR requirements, nicotine-containing e-cigarette products and refill containers can require information including:

• List of ingredients
• Nicotine content
• Nicotine delivery per dose
• Batch number
• Recommendation to keep the product out of the reach of children
• Required health warning
• Instructions and storage information
• Contraindications
• Warnings for specific risk groups
• Possible adverse effects
• Addictiveness and toxicity information
• Producer or importer details
• An accompanying information leaflet

The required nicotine warning on the unit packet and container pack is: “This product contains nicotine which is a highly addictive substance.”

The exact layout, text size, positioning and regional requirements should be checked by the producer or its regulatory adviser before the artwork is approved.

MHRA Product Notification

A business that manufactures, imports or rebrands a nicotine-containing e-cigarette or refill container may be treated as a producer and may need to submit a product notification.

Products must appear on the appropriate MHRA published list before they can legally be supplied in the relevant market. Great Britain and Northern Ireland use separate published product lists for newer notifications. Publication does not by itself guarantee that the physical packaging and labelling are compliant.

Packaging artwork can include space for:

• Product identifiers
• ECID or internal references
• Batch codes
• Importer details
• Manufacturer details
• Market-specific information
• Variable labels

The producer remains responsible for confirming the final content.

Packaging for Adult-Only Products

Vape packaging should be created for adult consumers and should not be designed to appeal primarily to children or young people.

Nicotine-containing vaping products cannot be sold to anyone under 18 in the UK, and retailers are required to operate suitable age-verification policies.

Artwork should therefore be reviewed carefully when it includes:

• Cartoon characters
• Child-directed illustrations
• Toy-like designs
• School-related themes
• Youth-focused language
• Sweet or soft-drink imitation
• Bright graphics likely to create child appeal
• Celebrity or influencer imagery

The responsible brand should approve the design against all current advertising, promotion and packaging requirements.

Changing UK Vape-Packaging Rules

The Tobacco and Vapes Act became law on 29 April 2026 and gives governments powers to introduce further restrictions affecting vape packaging, branding, device appearance, flavour descriptions and retail displays.

A UK-wide consultation opened in July 2026 on proposed new restrictions covering colours, images, branding and other packaging features. These are proposals rather than final packaging rules at the time this content was prepared. Artwork should be checked against the regulations actually in force when the order is approved and when the product is placed on the market.

This is especially important for brands planning long production runs or packaging intended to remain in circulation for several months.

Vaping Products Duty and Packaging Space

The UK government is introducing Vaping Products Duty from 1 October 2026. The duty applies to vaping liquid whether or not it contains nicotine, at a stated rate of £2.20 per 10ml.

HMRC may use the volume shown on retail packaging when calculating the duty. Businesses should therefore ensure that liquid-volume information is accurate and allow space for any duty-related marks or stamps required under the final scheme.

All tax and duty information should be confirmed with HMRC or a qualified adviser before printing.

Box Structures and Closures

Straight Tuck-End Boxes

Both closing flaps fold in the same direction. This creates a clean front and back panel and works well for cartridges, bottles and pods.

Reverse Tuck-End Boxes

The top and bottom flaps close in opposite directions. This format is commonly used for lightweight retail cartons.

Lock-Bottom Boxes

A reinforced folding base provides more support for bottles, devices and heavier products.

Two-Piece Boxes

A separate lid fits over a base tray. This format works well for premium devices and gift-style starter kits.

Drawer Boxes

An internal tray slides from an outer sleeve. A ribbon pull or thumb notch can be included.

Magnetic Rigid Boxes

A concealed magnetic closure provides a firm premium opening for high-value kits and multi-component presentations.

The structure should be chosen according to the product weight, packing process and intended retail environment.

Printing Custom Vape Boxes

Vape packaging can be printed in full CMYK colour or matched closely to approved Pantone references.

Artwork can include:

• Brand name and logo
• Product type
• Device compatibility
• Flavour or variant information
• Nicotine strength
• Liquid volume
• Ingredients
• Required warning text
• Batch information
• Instructions
• Barcode
• QR code
• Manufacturer or importer details
• Product identifiers
• Recycling guidance

The layout should give required information sufficient contrast and separation from decorative graphics.

Small text should be reviewed on the physical sample rather than only at enlarged screen size.

Printing and Finishing Options

Available finishes may include the following, subject to current packaging rules and approved artwork.

Matt Lamination

Creates a low-reflection surface and can reduce light scuffing during handling.

Gloss Lamination

Adds shine and can make printed colours appear brighter.

Soft-Touch Lamination

Provides a smooth tactile finish for premium reusable devices and rigid kits.

Foil Stamping

Metallic foil can highlight suitable logos and controlled design details.

Embossing and Debossing

Embossing raises selected artwork, while debossing presses it into the board surface.

Spot UV

Creates a glossy highlight over selected parts of a matt design.

Interior Printing

Inside panels can include instructions, component diagrams, setup guidance or adult-oriented brand information.

Finishes should not reduce the visibility of mandatory warnings or make required text difficult to read.

Vape Boxes for E-Commerce Delivery

A printed retail carton is not always enough protection for courier delivery.

Cartridges, bottles and devices may need to be placed inside:

• Corrugated mailer boxes
• Protective shipping cartons
• Divided outer boxes
• Paper cushioning
• Tamper-evident delivery packs

The outer shipping box should reduce movement while protecting the printed retail packaging from crushed corners and surface damage.

Battery-containing products may also be subject to carrier and dangerous-goods requirements. The sender must confirm the correct transport rules for the device, battery and destination.

Related Packaging Ranges

The same structural and print approach can be used across related lawful products.

Explore:

• CBD Boxes for lawful oil, cosmetic and related product packaging
• Mylar Bags where a resealable barrier pouch is more suitable than a carton
• Custom Product Boxes for general retail packaging
• Display Boxes for permitted counter and shelf presentation
• Custom Mailer Boxes for e-commerce despatch

CBD, nicotine and other regulated products must each be reviewed under the rules that apply to their own contents and claims.

How Ordering Works

1. Send Your Product Details

Provide the product dimensions, weight, component list and required quantity.

Also confirm:

• Cartridge, pod or bottle capacity
• Nicotine or non-nicotine format
• Intended UK market
• Required warning panels
• Insert type
• Retail or e-commerce use
• Current approved artwork

2. Select the Structure and Materials

Our team will recommend a folding carton, rigid box, insert and any required outer shipping protection.

3. Review the Free 3D Mockup

You receive a digital presentation showing the proposed structure and artwork placement.

4. Approve the Physical Sample

A physical sample is produced, and you receive a video showing:

• Product fit
• Insert
• Warning and information panels
• Closure
• Hang tab or window
• Printed colours
• Small-text clarity
• Overall presentation

5. Production and Delivery

After final approval, production normally takes 6 to 8 business days. Completed orders include free delivery throughout the UK.

Order Custom Vape Packaging

To request an accurate quotation, provide:

• Product type
• Exact dimensions
• Packed weight
• Cartridge, tank or bottle capacity
• Required quantity
• Number of components
• Preferred box style
• Insert or divider requirements
• Required information panels
• Artwork and Pantone references
• Finishing preferences
• Retail or postal use
• Intended market within the UK

Our team will review the details and recommend a suitable structure and internal layout. Final regulatory text and product legality must be confirmed by the responsible producer, importer or regulatory adviser.

Frequently Asked Questions

What types of vape packaging do you produce?

We produce cartons and presentation boxes for lawful cartridges, replacement pods, refillable devices, starter kits, coils, accessories and e-liquid bottles.

Do you produce boxes for single-use disposable vapes?

No UK-focused packaging should promote products that cannot legally be sold. The sale and supply of single-use vapes has been banned throughout the UK since 1 June 2025.

Can cartridge boxes be made to exact dimensions?

Yes. Boxes and inserts can be developed around the cartridge length, width, diameter and protective container.

Can you make packaging for 0.5ml and 1ml cartridges?

Yes, where the product is lawful and compliant for its intended market. The exact dimensions and product specifications are required before the dieline is prepared.

Can the box include a hang tab?

Yes. Hang tabs can be added to suitable lightweight cartons where current retail-display rules permit them.

Can you add an insert?

Yes. Die-cut card, foam and divided inserts can hold cartridges, pods, bottles, devices and kit components.

Can required warning text be printed?

Yes. The artwork can reserve space for warning text and other information supplied and approved by the responsible business.

Does All Custom Packaging certify vape products as compliant?

No. We produce packaging to the approved specification. The producer, importer or product owner remains responsible for notification, testing, labelling and legal compliance.

Are nicotine e-liquid bottles limited to 10ml?

Nicotine-containing refill containers sold to consumers are currently limited to 10ml under UK TRPR requirements.

Can you make boxes for larger shortfill bottles?

Yes. Boxes can be produced for larger nicotine-free shortfills, subject to the product’s applicable safety, chemical, tax and labelling requirements.

Are clear windows available?

Yes. Clear windows can be added where they do not compromise the structure, required information or current packaging rules.

Can a retail vape box be used for courier delivery?

A lightweight retail carton may need a separate corrugated mailer or shipping box, especially for glass bottles, batteries and multi-component kits.

Can I approve the box before production?

Yes. You receive a free 3D mockup and can approve a video of the physical sample before the complete production run.

Is free UK delivery included?

Yes. Completed custom vape-packaging orders include free delivery throughout the United Kingdom.