Product Description
Our custom folding carton with insert tray is purpose-built for tea and coffee packaging — keeping sachets, loose-leaf pouches, tea bags, coffee capsules, and drip bags neatly organized and protected. The precision die-cut insert tray holds individual items securely in place, preventing movement during shipping while creating an elegant retail presentation. Every carton is printed on our KBA 1050 4-color offset press for rich, food-safe CMYK graphics and finished on the Heidelberg 7+1 UV line for optional spot UV, foil accents, and protective coatings. Manufactured by Guangdong Bincai Color Printing Co., Ltd. with 22 years of folding carton expertise (founded 2003) across 18,000 sqm (10,000+8,000 smart factory) of production floor in Foshan, Guangdong — daily output of 1.7 million boxes under ISO 9001:2015 and FSC Chain-of-Custody certification.
Features
- Custom Insert Tray: Die-cut cardboard tray engineered to your product dimensions — single-level, multi-level, and compartmentalized layouts for tea bags, coffee sachets, capsules, or loose-leaf pouches.
- Flat-Shipping Folding Design: Cartons ship flat and assemble quickly with tuck-top, auto-lock bottom, or glue-flap closures — reducing freight volume by up to 70% versus rigid boxes.
- CMYK Offset Printing: KBA 1050 4-color press delivers sharp, food-appealing graphics at up to 200 LPI with consistent color across production runs.
- Heidelberg 7+1 UV Finishing: Inline spot UV gloss, matte aqueous coating, or soft-touch lamination applied in a single pass for premium shelf presence.
- Food-Safe Materials: FSC certified paperboard, soy-based inks, and water-based coatings available for direct food contact applications.
- Window Patching Options: Die-cut windows with PET or PLA film let customers see the product inside while keeping contents protected.
- Value-Added Finishes: Hot foil stamping (gold, silver, copper), embossing/debossing, and custom insert printing for branded unboxing experiences.
Production Specifications
| Spec | Detail |
|---|
| Press | KBA Rapida 105 4-color at 15,000 sheets/hour + Heidelberg Speedmaster CD 102 7+1 UV |
| Substrate | 250–400gsm C1S/C2S art paper; 300–400gsm FSC kraft; 18–24pt SBS |
| Insert Tray | Custom die-cut greyboard 800–1200gsm, single-level or multi-level; ±0.3mm cavity tolerance |
| Printing | CMYK offset + spot Pantone colors; soy-based food-safe inks standard |
| Coatings | Inline aqueous, matte/gloss lamination, soft-touch velvet, spot UV |
| Die-Cutting | Bobst SP 102 flatbed with ±0.15mm precision; window and insert die-cut in single pass |
| Assembly | Automatic folding-gluing line for tuck-top, auto-lock, and crash-lock closures |
| Daily Capacity | 280,000+ folding cartons (dedicated line) |
| Lead Time | 8–12 working days new tooling; 5–7 days repeat orders |
Quality Assurance
| Test | Standard | Target |
|---|
| Color Consistency | ISO 12647-2 | ΔE ≤ 2.0 across production run |
| Food Safety | EU 1935/2004, FDA 21 CFR | Migration limits passed — soy-based inks, water-based coatings |
| Glue Bond | Internal Protocol | ≥90% fiber tear (substrate failure, not bond failure) |
| Folding Crease | Internal Protocol | ±0.5mm crease-to-trim alignment; zero cracking on 180° fold |
| Insert Fit | Custom QC Gate | ±0.5mm fit tolerance; product does not shift during ISTA vibration test |
| Window Adhesion | ASTM D3359 | Cross-hatch tape test — zero peel from PET/PVC window |
| ISTA 1A Drop Test | Drop from 762mm | Zero structural failure, zero insert displacement |
Applications
| Industry | Use Case | Recommended Spec |
|---|
| Specialty Tea | Loose-leaf tea pouch boxes, pyramid tea bag cartons | Kraft + soy ink + window patch |
| Coffee | Drip bag sets, capsule multi-packs, single-origin gift boxes | Matte lam + gold foil + 6-cavity insert |
| Confectionery | Premium chocolate, macaron, biscuit gift cartons | Gloss lam + spot UV + multi-level tray |
| Health & Wellness | Supplement sachet, herbal tea, wellness kit packaging | Soft-touch + embossed logo + compartment insert |
| Gourmet Food | Spice sets, seasoning mix multi-packs, cooking kit boxes | SBS + aqueous coating + tiered insert |
| Corporate Gifts | Tea & coffee sampler gift sets for B2B gifting | Rigid-feel greyboard + magnetic closure + satin ribbon |
