What is the most effective way to seal custom-printed coffee boxes?

Hayley Osbourne
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July 11, 2023
An image of a roll-end front tuck coffee box, custom-printed coffee box with custom-printed coffee bags, customised coffee box in an article on the most effective ways to custom-printed coffee boxes

The Covid-19 pandemic had a profound and long-term impact on coffee consumer behaviour. Many consumers were preparing their coffee at home, trying different origins and processing methods, as well as a range of brewing methods. As part of this, coffee subscription services have become more and more popular. 

Since 2019, the number of coffee roasters offering subscriptions has increased by 25%, with a 109% increase in sales, according to the SCA. While each subscription service will differ, most require customers to sign up to receive a specified number of bags of roasted coffee. Coffee is delivered to customers’ homes as often as they choose – typically on a weekly or monthly basis. Subscriptions can help ensure customers receive freshly roasted coffee when they need it.

While each subscription service will differ, most require customers to sign up to receive a specified number of bags of roasted coffee. Coffee is delivered to customers’ homes as often as they choose – typically on a weekly or monthly basis. Subscriptions can help ensure customers receive freshly roasted coffee when they need it.

To ensure coffee reaches customers in pristine condition, many roasters use custom-printed coffee boxes. These provide an additional layer of protection during transit while helping to showcase the brand.
Coffee boxes are available in several shapes and sizes. Making sure they are properly sealed keeps the coffee safe, thereby ensuring customers are satisfied time and time again. But what is the most effective way to seal custom-printed coffee boxes?

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Sealing customised coffee boxes: Why is it essential?

More roasters are realising the versatility of coffee boxes. Custom-printed coffee boxes allow for a more personalised customer experience, encouraging consumers to connect and interact with a brand. Research shows consumers tend to trust a brand more when the product arrives in premium packaging.

Customised boxes allow roasters to package, store, and ship coffee easily, all while boosting brand awareness without additional costs. They are typically used for coffee subscription services or gift boxes, but more roasters are using unique packaging to showcase new products. Sealing coffee boxes will prevent the beans from being contaminated during transit. Consumers are less likely to feel comfortable brewing coffee if there is a chance it has been contaminated.

An image of a kraft paper coffee box, sustainable coffee box, customised coffee box, roll-end tuck top coffee box, RETT box, in an article on the most effective ways to custom-printed coffee boxes

What is the most effective way to seal them?

Roasters have several box styles to choose from. Two of the most popular options include roll-end front tuck boxes (REFT) and roll-end tuck top boxes (RETT). The most noticeable difference between the two is how they close.

Roll-end front tucks boxes

To make REFT boxes, manufacturers ‌fold one piece of cardboard in on itself. Also known as mailer boxes, this packaging has additional rounded flaps on the lid that tuck securely into the front of the box. These flaps prevent the box from opening unexpectedly, meaning roasters will not have to tape the box shut. 

Roasters can choose to customise these further by adding more dust flaps. Adding these flaps to the side can provide extra support and block dust from entering the packaging. It is important to note that assembling REFT boxes takes time, as the flaps must be folded and secured. 

Roll-end tuck tops boxes

Alternatively, RETT boxes tuck the lid straight into the front of the box. These boxes provide a double layer of protection on both the bottom and sides. They can also be filled quickly as roasters don’t have to deal with folding additional flaps. Beyond this, RETT boxes are easy to customise because of their simple design. However, these boxes will need tape or labels to ensure they remain closed throughout distribution.

An image of custom-printed coffee box from Batch Coffee, compostable coffee box, kraft paper coffee box. customised coffee box, custom coffee box, in an article on the most effective ways to custom-printed coffee boxes

What to consider when investing in custom coffee boxes

Notably, both REFT and RETT boxes can be effectively customised in a number of ways. Some of the more important factors to consider when customising coffee boxes include:

Graphics versus text

A 2022 study found graphics can better support sensory product claims than text. Instead of overloading the packaging design with flavour notes, roasters can use images or graphics to describe the product.

Finding the right size

To ensure coffee boxes are designed for mailbox deliveries, it’s important for roasters to familiarise themselves with the size of the mailboxes in their distribution area.

Using sustainable materials

As well as being the right size, coffee boxes must also be made from sustainable materials. Recent studies show 86% of younger consumers are willing to pay more for sustainable packaging. Therefore, it is essential roasters choose materials that are eco-friendly and sustainable. This also applies to any inks and adhesives used to customise the box after its assembly.

Inks and labels can prevent coffee packaging from being sustainable. Ink needs to bond with the packaging’s surface to resist abrasion, water, and heat throughout its lifecycle. Furthermore, it can be difficult to remove, making recycling challenging if the inks contain harmful materials or have a non-renewable petroleum base. Labels can also keep the packaging from being sustainable if non-renewable adhesives are used to attach the label to the packaging’s surface. 

At MTPak Coffee, we understand how important it is to make sure your customers keep coming back. This is why we offer a range of custom coffee mailer boxes of various sizes to accommodate the mailboxes in your markets. Our custom coffee mailer boxes are made from recycled cardboard and are strong, durable, and weather resistant.

These highly customisable and recyclable coffee boxes can be used for ecommerce sales, coffee subscriptions, blind-tasting boxes, and more. Additionally, we offer a range of 100% recyclable coffee packaging options made from renewable materials such as kraft paper, rice paper, or multilayer LDPE packaging with an environmentally friendly PLA lining.

Choose from our range of coffee bag structures to ensure they fit perfectly into your coffee mailer boxes. All of our coffee packaging options can be fully customised to your specifications, including debossing, embossing, holographic effects, UV spot finishes, and custom printing using digital printing technology. As well as this, we offer sustainable custom-printed stickers that can be used on your coffee boxes.

Ask us about our low minimum order quantities (MOQs) for micro-roasters.

For more information on custom coffee mailer boxes, contact our team. 

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