Tuck Box Sizes: Standard Dimensions for Lip Balm, Serum, Soap, and Supplement Cartons

The Short Answer

Standard tuck box sizes by product: lip balm tube, 0.75 x 0.75 x 2.875 in; 1 oz dropper bottle, 1.5 x 1.5 x 4.25 in; 4 oz soap bar, 2.375 x 1.125 x 3.625 in; 60-count supplement bottle, 2.375 x 2.375 x 3.875 in; poker deck, 2.5625 x 0.8125 x 3.5625 in.

Every figure here is an inside dimension in Length x Width x Depth format, the convention carton converters print on quotes and dielines.

How to Read Tuck Box Dimensions (L x W x D)

Tuck box dimensions run Length x Width x Depth, measured inside the carton. Length is the longer side of the opening, Width is the shorter side, and Depth is the distance between the top and bottom tuck flaps.

Order changes the box: a 2 x 1 x 5 in carton stands upright like a serum carton, while a 5 x 1 x 2 in carton opens along its long face and lies flat.

Outside dimensions add board caliper: 18pt SBS measures 0.018 in (0.46 mm), so an 18pt carton runs roughly 0.04 in larger than its inside size each way. Use outside dimensions for case packs and shelf facings.

Tuck End Box Size Chart by Product Type

This tuck end box size chart lists standard tuck box dimensions for eleven products, using assembled heights with the cap or dropper fitted. Measure your own component before approving a dieline, because suppliers vary.

The Clearance and Board Rules Behind the Chart

Three rules produce every row above, and they apply to all folding carton sizes, including products this chart does not list.

Side clearance: add 1/16 to 1/8 in per side to the widest point, toward 1/8 in for glass, paper labels, and shrink bands.

Depth clearance: add 1/8 to 1/4 in to the assembled height, toward 1/4 in when a cap, pump, or dropper bulb sits under the tuck flap.

Board caliper: 14pt (0.014 in) for non-glass products under 4 oz filled; 18pt (0.018 in) for all glass and for products from 4 to 8 oz; 20pt to 24pt above 8 oz or for cartons that ship without an outer mailer.

Playing cards are the one exception: 1/32 in per side and 1/16 in total in depth, because a deck that shifts inside its box scuffs the card edges.

Lip Balm Boxes: 0.75 x 0.75 x 2.875 Inches

Standard lip balm box dimensions are 0.75 x 0.75 x 2.875 in. A 0.15 oz (4.25 g) tube measures about 0.6 in across and 2.65 in tall with its cap, leaving roughly 0.075 in per side and 0.225 in of depth clearance.

A filled tube weighs under half an ounce, so it runs on 14pt. Brands skipping single cartons sell tubes from counter dispenser boxes of 12, 24, or 50 units. Classic lipstick bullets at about 0.85 x 3.0 in move to a 1 x 1 x 3.25 in lipstick carton, also on 14pt board since the case is metal or acrylic, not glass.

Dropper Bottle Boxes: 1 oz Serums Fit 1.5 x 1.5 x 4.25 Inches

The standard dropper bottle box size for a 1 oz (30 ml) serum is 1.5 x 1.5 x 4.25 in. A 1 oz glass Boston round measures about 1.3 in across and 4.0 in tall with its pipette and rubber bulb fitted. Measure to the top of the bulb, not the shoulder: the dropper adds roughly 1 in.

The 1.5 in carton gives 0.1 in per side, inside the 1/16 to 1/8 in glass range, with room for an 18pt paperboard collar at the shoulder that stops the bottle striking the walls in transit. The 0.5 oz and 2 oz sizes scale to 1.125 x 1.125 x 3.75 in and 1.75 x 1.75 x 5.25 in. All three are glass on 18pt board with reverse tuck ends, so brands selling the full range print the three cosmetic boxes as one gang run to share plate costs.

Soap Boxes: End-Loading Cartons for 4 oz and 5 oz Bars

Soap cartons load through the short end, so the bar’s width and thickness set the opening and its length sets the depth. A 4 oz bar at 3.5 x 2.25 x 1 in takes 2.375 x 1.125 x 3.625 in. A 5 oz loaf-cut bar at 3.25 x 2.5 x 1.25 in takes 2.625 x 1.375 x 3.375 in. Both run on 18pt board.

Cold process soap loses water through its 4 to 6 week cure, so size to the cured bar and add a vent hole so released moisture does not soften the board. Straight tuck ends put both flaps on one panel for face-up shelf display, and natural kraft is a common board for handmade soap.

Supplement Bottle Boxes: Size the Panel, Not Only the Bottle

Supplement cartons follow the packer bottle, and packer bottles follow capsule count. Most brands find 60 size 00 capsules fill a 120 to 150 cc bottle and 120 capsules fill a 250 cc bottle. A 150 cc HDPE packer measures about 2.2 x 3.7 in with its cap and fits 2.375 x 2.375 x 3.875 in; a 250 cc packer at about 2.6 x 4.7 in fits 2.75 x 2.75 x 4.875 in.

A filled 60-count capsule bottle weighs roughly 2 oz and runs on 14pt; a 120-count bottle reaches about 4 oz and moves to 18pt. Weigh tablet and powder formulas, which run heavier.

The Supplement Facts panel required under 21 CFR 101.36, the ingredient statement, and the manufacturer address all print on the carton’s information panel. Lay out the full label on the dieline before locking the carton width, because a long formula can outgrow a 2.375 in side panel. Auto-lock (crash-lock) bottoms replace the bottom tuck and hold a filled bottle without pushing open.

Playing Card Boxes: The Snug-Fit Exception

A poker card measures 2.5 x 3.5 in (63 x 88 mm), and 54 cards on 310 gsm casino stock stack to about 0.75 in, so the standard poker tuck box is 2.5625 x 0.8125 x 3.5625 in. Bridge cards at 2.25 x 3.5 in (57 x 89 mm) use 2.3125 x 0.8125 x 3.5625 in.

A 54-card deck weighs about 3.4 oz, inside the 14pt band. Sleeved decks need their own dieline, since 66 x 91 mm sleeves add width and roughly 0.2 to 0.4 in of thickness per 54 cards. Card boxes use straight tuck ends with a half-moon thumb notch on the front panel.

Confirm Fit Before Printing

An unprinted structural sample confirms fit before plates are made; a sizing error caught after printing means paying plate costs twice. Packify produces tuck end cartons cut to your exact dimensions, so no size in this chart is a fixed menu.