Custom Sandwich Boxes

Custom sandwich boxes are made-to-size food packaging solutions for deli sandwiches, club sandwiches, wraps, panini, breakfast sandwiches, subs, baguettes, sliders and takeaway meal combinations. BoxBaba offers triangular sandwich wedge boxes, window cartons, hinged clamshells, tuck-top boxes, tray-and-sleeve packaging, long sub boxes, gable carriers and compartment meal boxes. Choose kraft paperboard, white cardboard, grease-resistant paperboard or E-flute corrugated board with custom logo printing, windows, dividers, liners, ventilation holes and carry handles. Orders start from 100 units, with custom sizing, artwork support, sample options, production in 5–9 business days after artwork approval and free shipping across the USA.

4.3

Reviews 8 • Excellent

Thais Miller

Greatest P......

Christina at BoxBaba has been amazing at guiding us through the process of acquiring…

Professional, great communication, great quality. Thank you so…

My contact at BoxBaba, Marcel, was very tentative and responsive. He gave me all box outlines…

These guys are legit Top-notch service and high quality products.

We recently purchased box sleeves and we couldn’t be happier with both the product and the service we received…

For our recent product launch, we needed packaging that would really make an impression. The custom boxes from BoxBaba…

I’ve been very pleased with my experience with BoxBaba and Cristina from Customer Service to communicate our…

Absolutely phenomenal service and product! David Wells far exceeded expectations to deliver high-quality custom…

Date of experience:

Jul 9, 2025

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Upload Your Design

Design

Get your custom boxes made in the required size, shape, and style.

Print

Upload your artwork and get it superbly printed the way you want.

Get it done

Order any quantity, enjoy a wholesale price, pay no extra for die plates.

Product Specification

Specification	Details
Box Style	Fully customizable Sandwich Boxes folding carton, magnetic closure, drawer, shoulder neck, mailer, or specialty box styles
Dimensions (L × W × H)	Custom sizes manufactured according to your exact product dimensions and structural requirements
Order Quantity (MOQ)	100 units minimum (flexible for specific projects)
Material Options	10pt–24pt SBS Kraft board, corrugated (B, E flute), high-density greyboard for rigid boxes
Printing Options	CMYK offset printing, Pantone (PMS) color matching, inside & outside printing
Print Finishes	Matte lamination, Gloss lamination, Soft-touch coating, Aqueous coating, UV coating
Premium Enhancements	Foil stamping (gold/silver/custom colors), Embossing, Debossing, Spot UV, Raised UV
Insert Options	EVA foam inserts, Die-cut paperboard inserts, Molded pulp, Cardboard dividers, Custom fit structural inserts
Embellishments	Ribbons, magnetic closures, bows, glitters, sparkles, custom tags & hang tags
Compliance Support	Labeling guidance & compliance support available for regulated products including hemp/CBD packaging
Sampling & Proofing	Free 3D digital mockups, blank sample, printed sample (delivery reimbursable)
Production Timeline	5–9 business days standard production (rush orders available upon discussion)
Shipping	Free USA shipping; flat-packed or assembled shipping options available

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Stock Type & Thickness

Finishing Assortment

Custom Printed Sandwich Packaging for Cafés, Delis and Takeaway Brands

Custom sandwich packaging should be designed around the complete food portion rather than the sandwich name alone. The box must account for the bread shape, filling depth, toppings, wrapping paper, serving orientation and any side items included with the order. A cold triangular sandwich may require a compact wedge carton that holds both halves upright. A heavily filled club sandwich needs additional depth to prevent pressure on the bread and ingredients. BoxBaba manufactures custom printed sandwich boxes for cafés, sandwich shops, delis, bakeries, restaurants, food trucks, caterers, convenience stores, supermarkets, meal-prep businesses and delivery operations. Businesses developing packaging for a wider takeaway menu can also explore Custom Food Boxes.

Sandwich Products That Can Be Packaged

Custom dimensions and structures can be developed for:

Club sandwiches
Deli sandwiches
Triangular sandwiches
Tea sandwiches
Submarine sandwiches
Baguette sandwiches
Panini and grilled sandwiches
Toasted sandwiches
Sandwich-and-side meal combinations

The finished sandwich should be measured after it has been assembled, wrapped and prepared in the same way it will be packed during normal service.

Choose the Right Sandwich Box Structure

Triangular Sandwich Wedge Boxes

Sandwich wedge boxes are designed for triangular sandwich halves displayed in an upright position. They are suitable for cafés, convenience stores, grocery displays, grab-and-go counters and refrigerated retail presentations.

Window Sandwich Boxes

A window sandwich box allows customers or retail staff to view part of the packaged food without opening the carton. Windows can be added to wedge, rectangular, clamshell or sleeve-style structures..

One-Piece Takeout Lock Boxes

One-piece takeout boxes use an integrated folded structure with locking tabs or flaps. They can suit sandwiches, panini, wraps, sliders and takeaway portions that need a more enclosed format.

Hinged-Lid Clamshell Boxes

A clamshell box combines the base and lid within one connected structure. It provides quick opening and closing for takeaway counters, cafés, diners, food trucks and delivery operations. Businesses packaging burger-focused menu items can compare this format with Custom Burger Boxes.

Tuck-Top Sandwich Boxes

Tuck-top boxes use a lid or flap that inserts into the front or side of the carton. They can suit individual sandwiches, bakery sandwiches, croissant sandwiches, wraps and compact meal portions.

Tray-and-Sleeve Sandwich Boxes

A tray-and-sleeve structure combines an inner tray with a separate printed sleeve. It can support organized presentation for premium sandwich sets, tasting selections, catering portions and branded retail packs.

Gable Sandwich Meal Boxes

Gable boxes combine an enclosed meal compartment with an integrated carrying handle. They may suit corporate lunches, school meals, catering orders, event packs and sandwich combinations containing snacks, fruit, napkins or cutlery.

Compartment Sandwich Meal Boxes

Compartment boxes organize sandwiches, fries, fruit, snacks, sauces or desserts within one outer package. Compartments may be created through a folded structure, removable divider or fitted insert..

Material Options for Sandwich Packaging

Food-Grade Paperboard

Food-grade paperboard may be used for lightweight folding cartons, wedge boxes, tuck-top structures and clamshell packaging. The selected board, coating, printing system and intended food-contact conditions must be reviewed together.

White Cardboard

White cardboard provides a bright surface for detailed graphics, product photography, menu information and multicolor branding. It may be suitable for retail cartons, takeaway boxes and window packaging where high print contrast is required.

Natural Kraft Paperboard

Natural kraft paperboard provides a brown, unbleached visual appearance that can suit cafés, delis, bakeries and takeaway brands seeking a simple material-led presentation.

Recycled Paperboard

Recycled paperboard may be considered where available and suitable for the intended structure. Surface color, texture, print consistency and food-contact requirements should be confirmed for the selected board rather than assumed from the material name alone.

Grease-Resistant Paperboard

Grease-resistant paperboard or an application-specific coating may be considered for sandwiches containing oils, butter, sauces, cheese or moist fillings.

E-Flute Corrugated Board

E-flute corrugated board may provide additional structural support for larger meal boxes, catering packs, gable carriers and heavier sandwich combinations.

PET or PLA Window Film

PET or PLA film may be used for selected window configurations. The film choice should reflect visibility, structural compatibility, storage conditions and any project-specific material requirements.

Custom Printing for Sandwich Boxes

Custom sandwich boxes can display logos, brand colors, product names, sandwich varieties, heating or storage instructions, ingredients, promotional messages, QR codes, barcodes and order-identification areas. Available printing methods include:

CMYK printing: Suitable for multicolor artwork, illustrations, gradients and photographic designs.
PMS printing: Useful when selected brand colors require more controlled color matching.
Offset printing: Supports detailed artwork and consistent printed presentation for suitable paperboard projects.
Digital printing: Can be practical for shorter runs, samples, seasonal packaging and multiple artwork versions.
Flexographic printing: Commonly considered for corrugated packaging and simplified artwork produced at suitable volumes.

The appropriate printing method depends on the material, box structure, artwork complexity, order quantity and required color result.

Finishing Options

Finishing options can improve the appearance, texture and surface protection of custom sandwich boxes. The best finish depends on the selected material, artwork and intended food use. Choose from the following options:

Matte Lamination – for a smooth, non-shiny look
Gloss Lamination – for a bright and shiny appearance
Aqueous Coating – for light surface protection
Grease-Resistant Coating – for protection against oil and moisture
Spot UV – for highlighting logos and selected artwork
Embossing – for raised logo or design details
Debossing – for pressed-in artwork details
Foil Stamping – for metallic logo and text accents
Window Patching – for clear product visibility

Inserts and Functional Add-Ons

Cardboard Dividers: Separate sandwich halves, varieties or side items.
Sauce Cup Holders: Keep fitted sauce containers upright and reduce movement.
Fry and Side Compartments: Organize fries, fruit, chips, salads or desserts.
Greaseproof Paper Liners: Help manage grease and can include custom printing.
Ventilation Holes: Release some heat and steam from hot sandwiches.
Carry Handles: Support convenient carrying for gable and meal boxes.
Tamper-Evident Seals: Help secure takeaway and delivery packaging.
Napkin and Cutlery Holders: Keep serving accessories organized in larger meal boxes.

Reference Sandwich Box Dimensions

The following dimensions can be used as preliminary reference points. They are not universal standards and the final size should be based on the actual food portion and selected structure.

Standard sandwich wedge: 4.8 × 4.8 × 1 inch
Deep-fill sandwich wedge: 4.8 × 4.8 × 2–3.2 inches
Rectangular sandwich box: 6 × 4 × 2.5 inches
Standard clamshell box: 7 × 3 × 2.625 inches
Long sub or baguette box: 10 × 3.5 × 3 inches
Standard sandwich meal box: 8 × 6 × 3 inches

Custom sizing is available for products that do not align with these reference dimensions.

Packaging Considerations for Hot and Cold Sandwiches

Cold sandwiches may suit compact wedge or window boxes that support visibility and product identification. Hot sandwiches may require clamshell or lock-style boxes with suitable ventilation to manage steam and heat. For oily or heavily sauced products, test the board, coating and liner with the actual food. Delivery packaging should also provide secure closure, stacking strength and enough internal space to prevent movement or pressure on toppings.

Our Custom Packaging Process

1. Share Your Requirements

Provide the sandwich dimensions, photographs, required quantity, preferred structure, artwork and delivery information.

2. Review the Structure

The structure is evaluated according to product shape, packed depth, weight, closure, display direction and any required compartments.

3. Prepare the Dieline

Artwork is placed on the dieline after the structure and dimensions have been confirmed.

4. Review the Proof

Check logos, text, colors, window position, cut lines, folds and functional areas before approving production.

5. Approve the Sample or Specification

A sample or final specification can be reviewed where required. Free sample options are available and eligible sample charges can be reimbursed with the first bulk order.

6. Production and Shipping

The standard production turnaround is 5–9 business days after artwork approval. Free shipping is available across the USA.

Why Choose BoxBaba for Sandwich Packaging?

Minimum order quantity starting from 100 units
Custom dimensions based on the finished sandwich
Multiple wedge, clamshell, tuck, sleeve, sub and meal-box structures
Kraft, white cardboard, grease-resistant paperboard and corrugated options
Custom logo and artwork printing
Window, divider, liner and compartment options
Artwork support
Free sample options
Eligible sample-charge reimbursement with the first bulk order
Standard production in 5–9 business days after artwork approval
Free shipping across the USA

Request a Quote for Custom Sandwich Boxes

Create sandwich packaging around the actual food portion, serving method and delivery requirements. Share your sandwich dimensions, preferred box structure, quantity and artwork with BoxBaba for a custom quotation. Call +1 305 574 4357 or email sales@boxbaba.com to discuss your custom sandwich packaging requirements.

Frequently Asked Questions

Find all the urgent questions you may have.

What are custom sandwich boxes?

Custom sandwich boxes are made-to-size cartons developed for specific sandwich formats, portions and service conditions. Their dimensions, structure, material, printing, windows and internal components can be configured according to the product.

What is the best box for triangular sandwiches?

A sandwich wedge box is commonly suitable for triangular sandwich halves. The required depth depends on the bread thickness, number of layers and amount of filling. Deep-fill sandwiches may require a wider wedge.

Can you produce sandwich boxes with windows?

Yes. Windows can be added to selected wedge, rectangular, clamshell and sleeve-style boxes. The position should be planned around the sandwich orientation, artwork and structural folds.

Can sandwich boxes be printed with a logo?

Yes. Logos, brand colors, product names, menu information, QR codes, barcodes and other approved artwork can be printed on the available exterior panels.

Which material should I choose?

The appropriate material depends on the sandwich weight, grease level, temperature, holding time, box structure, printing requirements and delivery conditions. Kraft and white paperboard may suit folding cartons, while E-flute corrugated board may be considered for larger or heavier meal packs.

Do hot sandwiches need ventilation holes?

Ventilation may be considered for hot sandwiches where trapped steam is a concern. The hole size and position should be tested because ventilation can also affect heat retention, containment and box strength.

Do I need a divider or insert?

An insert may be useful when the box contains sauce cups, sides, several sandwich portions or products that move during delivery. It may be unnecessary for a single sandwich that already fits securely.

Can you make boxes for subs and baguettes?

Yes. Long rectangular boxes can be produced according to the complete length, width and height of the sub or baguette.

Are custom sizes available?

Yes. Custom dimensions can be developed around the finished sandwich, selected structure, liner, inserts and required internal clearance.

What is the minimum order quantity?

The minimum order quantity starts from 100 units.

How long does production take?

The standard production turnaround is 5–9 business days after artwork approval.

Do you provide samples?

Free sample options are available. Eligible sample-related charges can be reimbursed with the first bulk order.

Is shipping available across the USA?

Yes. BoxBaba provides free shipping across the USA.

Custom Sandwich Boxes