Gable Boxes

How a Gable Box Goes Together

A gable box is cut from a single sheet. Four body panels form the walls, a self-closing (auto) bottom locks the base, and two sloped roof panels meet at the top. A handle hole is die-cut through both roof panels, and the panels lock together so the handle holds the box shut.

The box ships flat. At packing, the base pops into place as the walls open, the contents go in, and the roof panels fold up and lock. The whole outer surface is printable, including the roof and handle area.

Handle Height and Proportion

Handle height is set by how far the roof panels rise above the body. Too low, and fingers struggle to fit through the cut-out. Too tall on a small box, and the roof looks out of proportion and flexes more when lifted.

The handle is the part that takes the strain on every lift, so it is the first thing to tear when a box is overloaded. Board choice and handle height should be decided together, based on what the filled box will weigh.

Matching Board to Load

Paperboard is quoted in gsm or in points (thousandths of an inch). Approximate equivalents for coated board: 16 pt is about 300 gsm, 20 pt about 350 gsm, and 22 pt about 400 gsm. An 18 pt board sits between the first two.

As a working guide, not a tested rating:

• About 300 gsm: very light fills, roughly under 200 g.
• About 350 gsm: fills of roughly 200 to 500 g.
• About 400 gsm: fills above 500 g, or boxes carried repeatedly by the handle.
• B-flute corrugated (about 1/8 in): heavier loads, rougher handling and better puncture resistance.
• Fine flute corrugated: a middle option when you want more stiffness without bulk.

For dense items, test a filled sample before committing to a run, and move up a grade if the handle area creases when lifted.

Typical Size Range

These are planning sizes; final dimensions are set to your contents at quoting.

• Extra small: about 8 x 5 x 4 cm, for a single small item.
• Small: about 12 x 8 x 6 cm, or a compact 100 x 70 x 105 mm style.
• Medium: about 18 x 12 x 9 cm, or a 4 x 4 x 6 in tall format.
• Large: about 25 x 18 x 12 cm.
• Extra large: about 30 x 22 x 15 cm and up.
• Corrugated: 8.5 x 5.5 x 4 in and 10.75 x 8 x 5 in are common B-flute sizes.

Closure and Window Options

Two top closures are common. The handle closure locks the roof panels around the carry hole. A tuck-top version closes the roof with a tuck flap instead, for display where a handle is not needed.

A window can be die-cut into a side panel and backed with clear film, which is a separate material from the board. Gloss, matte or soft-touch lamination, spot UV, foil and embossing are optional finishes.

If the box will carry food, wrap or line the contents; food-contact-appropriate materials can be specified where required. Food-service gable formats are covered on the bakery boxes industry page.

When a Gable Box Is the Right Style

• Choose a gable box when the recipient carries it by hand without a bag: event giveaways, small gift sets, stationery kits and small clothing sets.
• Choose a tuck boxes style page when the product sits on a shelf and does not need carrying.
• Choose a mailer boxes style page when the box goes into the post; a gable handle is not built for parcel networks.
• Choose a rigid boxes style page when the box must be kept; a gable box is lighter, ships flat and costs less to store.

MOQ starts from 100 on select standard sizes; corrugated and windowed builds can raise the floor. Send your contents and their weight, and

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