A custom cigar box is a printed box cut to the exact length, ring gauge and count of your cigars, used by boutique blends, private labels, gift sets and event giveaways. TBPB makes them to your dimensions with no minimum order, and we will beat a written quote for the same specs.
Sizing by length, ring gauge and count
Cigars are sized by length in inches and ring gauge, which is the diameter in 64ths of an inch. A robusto is commonly around 5 inches long at a ring gauge near 50, which makes it a little under an inch wide, but blends vary, so measure yours. For a box, lay the cigars the way they will sit, whether in one flat layer or stacked, and measure the total footprint. Add about 1/8 inch of clearance on the length and a little on the width so cigars slide in and out without scuffing the wrapper. Common counts are 5, 10, 20 and 25, but we can build for any count you need.
Structure and board
Cigar packaging usually calls for a firm box, since a crushed box means crushed cigars. Our rigid options include a lid and base, a slide drawer and a shoulder-neck style, and the right one depends on how you want the box opened. The more formal your brand, the more a slide drawer feels like a reveal. For lighter use, such as a single-cigar sleeve or a gift pack, a folding carton in 16 to 24 pt paperboard keeps cost and weight down. For rigid builds, chipboard around 1.5 to 3 mm wrapped in printed paper is standard. See also our cigar boxes page, which covers the rigid-style builds, and two-piece boxes for the simplest lid and base structure.
Print and finish choices
Printed paper wraps can carry full-color CMYK, Pantone matches for the brand band color, foil stamping for the name and embossing for the crest. A matte laminate looks restrained and a gloss one looks bright. Many cigar brands keep a dark wrap with a single gold or copper foil mark, which reads as traditional without much decoration. Spot UV can pick out a pattern on a matte surface. Paper wrap printing does not make a box a humidor, though. It will not control humidity, so tell your customers to keep cigars in a proper humidor and treat the box as presentation and transit packaging.
If you are launching a new blend, order in two steps. First a single printed sample to check the cigar fit, the wrap color against your band and how the lid or drawer moves. Then the production run. Colors on a foil or dark wrap can shift from a screen proof, and a drawer that is a hair too snug will scrape the cellophane on every cigar. Because there is no minimum order, a sample is a small step that can save a large reprint.
- Rigid lid and base, drawer or shoulder-neck structures
- Folding carton option for light-weight packs
- Counts of 1, 5, 10, 20, 25 or your own
- Foil, embossing, spot UV, matte, gloss, soft-touch
- Paperboard or foam insert to hold each cigar in position
What you are responsible for
Tobacco products carry federal and state labeling and warning requirements. Those are your responsibility, and you should confirm them with your own regulatory adviser before artwork is final. We print the files you send and we do not add or check legal copy. For a related product, browse the cigarette and cigar box category.
Next step: send the cigar length, ring gauge, count and a quantity, even one. We draw the dieline and quote it.
Frequently asked questions
What are custom cigar boxes?
Custom cigar boxes are printed boxes made to fit the length, ring gauge and count of your cigars. They are used by boutique brands, private labels, gift sets and events, and are produced as rigid boxes or lighter folding cartons depending on the use.
Is there a minimum order for cigar boxes?
No. TBPB has no minimum order, so you can order a single box to check the fit and finish, or thousands for a full release. The same structures, print methods and finishes are available at every quantity.
How do I size a cigar box?
Measure the cigar length, and the ring gauge or diameter, then decide how they sit in the box. Add about 1/8 inch of clearance on the length and a little on the width. Send us the numbers and the count, and we draw a custom dieline.
Will a printed cigar box keep cigars fresh?
No. A printed paper-wrapped box is presentation and transit packaging, not a humidor. It does not control humidity, so tell customers to store cigars in a proper humidor or follow your own storage guidance.
What finishes suit a cigar brand?
Foil stamping and embossing on a dark matte wrap are the classic choice. Spot UV can pick out a pattern, soft-touch gives a quiet feel, and a Pantone match keeps your brand band color consistent from box to band.
Do you add tobacco warnings to the box?
No. We print only the artwork you supply. Federal and state tobacco labeling and warning rules are your responsibility, so confirm what your product needs with your own regulatory adviser before sending final files.
More Cigarette Boxes
See the full Cigarette Boxes range, or explore related options with no minimum order and our best-price guarantee:
