Materials and Structures

The material is the first thing a hand touches. It changes how a bottle sits, how a logo prints, how the box survives a courier van. This page covers what we use, what we avoid, and how to combine board, facing paper, structure and insert for your own job.

Board weight matters

We build wine gift boxes on greyboard at 1200 g minimum. For spirits and heavier bottles, 1400 g is the safer pick. Lower weights dent too easily. The greyboard is virgin fibre, not recycled, and we reject any sheet with high moisture content before it reaches the cutter. Facing paper starts at 157 g, specialty or coated. Lighter facing wrinkles during lamination. The board gives the box its body; the facing gives it the look. Get both right and the box stays square on a shelf.

Rigid greyboard wine box with specialty paper facing

Six common materials

Greyboard with specialty paper

The standard for rigid lid-and-base gift boxes. Greyboard provides stiffness, specialty paper takes fine print and foil well. It is the most reliable combination for single and double bottle presentations.

Kraft paper

Used for shipping boxes and some foldable gift boxes. It prints cleanly in one or two colours and hides scuffing better than coated papers. Not the pick for high-end foil work.

White card

A bright, smooth base for full-colour printing. White card makes colours pop, but it shows every fingerprint. We use it mainly for foldable boxes and inner trays, not outer rigid shells.

Gold and silver cardboard

Metallic facing for premium gift lines. It foils and debosses well, but scratches are visible. We recommend a soft-touch lamination over metallic board if the box will be handled often.

Flocked paper

A velvet-like surface for the inside of the box or the insert tray. It feels expensive and protects the bottle from micro-scratches. Flocking is delicate, so we keep it away from high-wear outer surfaces.

Leather-textured paper

A paper facing that looks like leather without the cost of real hide. It takes blind embossing and foil stamping well. We use it for magnetic closure boxes and premium single bottle sets.

Six box structures

Rigid lid-and-base

The classic two-piece gift box. The lid lifts off to reveal the bottle. It feels substantial and is the best structure for a high-end unboxing moment.

Magnetic closure

A hinged lid with hidden magnets. The close is quiet and firm. Buyers often choose this for corporate gifts because it feels engineered, not just folded.

Drawer

A sliding tray inside a sleeve. Good for double bottle sets or boxes that include accessories. The pull-out motion adds a second reveal step.

Foldable

Ships flat and erects in seconds. Cheaper to freight and store. We control crease depth so the folds do not crack, and magnet position to plus or minus 1 mm.

Double-door

Two side panels open from the centre. Works well for wide format boxes and for wine bags with a structured base. It creates a symmetrical reveal.

With handles

A rigid box with a rope, ribbon or die-cut handle. Practical for larger formats. The handle attachment point needs reinforcement or it will tear through the facing paper.

Four insert types

Velvet tray

A flocked tray that cradles the bottle. Soft against the glass, but velvet trays add height. We use them when the box is deep enough to keep the neck supported.

EVA foam

Dense foam cut to the bottle profile. Holds the bottle at four points and absorbs shock well. EVA is the best insert for shipping boxes and long-distance courier routes.

Blister

A clear plastic shell that shows the bottle while holding it. Blisters are rigid and cheap, but they can look industrial. We suggest them for retail shelf boxes, not luxury gift sets.

Paper mould

Moulded pulp, also called paper mould. It is recyclable and lightweight. We use it for foldable boxes and eco-focused lines. It is less precise than EVA, so we add a plus or minus 1 mm tolerance check.

How to pick a combination

Start with the bottle, not the box. Give us the bottle dimensions or send a sample. The insert is the first decision: does the bottle need to survive a drop test or just look good on a desk? For shipping, EVA foam is the safe call. For a gift that stays in the room, a velvet tray or paper mould is enough. The insert must hold the bottle at four points. No unsupported neck or shoulder. We shake the box for ten seconds, tilt it 45 degrees, and invert it. If the bottle moves, the insert goes back to the drawing board.

Then pick the structure. Rigid lid-and-base for a premium reveal. Magnetic closure for a quiet, firm close. Foldable if freight cost matters. Drawer if you have two bottles or accessories. The facing paper comes last because it is the easiest to change. Specialty paper for fine print and foil. Kraft for a rustic look that hides wear. Flocked paper for the inside. Leather-textured paper for a premium feel without the hide cost. Our control tolerance is plus or minus 1 mm on inserts, plus or minus 2 mm on the box body. Corners must be 90 degrees when erected. If a foldable box crease cracks, it is rejected.

Buyer questions

Which material is best for a wine gift box that will be shipped?

For shipping, use greyboard at 1400 g with an EVA foam insert. The foam holds the bottle at four points and absorbs impact. The heavier board resists crushing. We run a 1.2 m six-face drop test with the bottle loaded and a stacking top load of 40 kg for 24 hours before any box leaves the factory.

Can I get a sample before mass production?

Yes. We make two sample types. A blank sample shows the structure, board weight, and insert fit. A printed sample shows the final facing paper, colours, and finishing. Send your box dimensions or bottle sample, reference design, quantity, and any special requirements to start.

What are the order size options for custom wine gift boxes?

We work with flexible MOQ for custom orders. Small runs and larger programmes are both possible. Tell us your target quantity and we will suggest the most cost-effective structure and material combination. Sample before mass production is always available.

Not sure which material fits?

Send the bottle and the market it ships to. We propose board, facing paper and insert together.