Custom Sandwich Boxes from Prime Custom Packaging use fold-over wraps and hinged trays built for subs, paninis, and wraps. Grease-resistant coatings keep sauces and oil from soaking through, while foil-lined pouches hold rolled shape and heat. Full CMYK printing brings deli and restaurant branding onto every piece. There is zero minimum order quantity and every order ships free across the United States. Our design team builds a free mockup before production begins. Order today for reliable, food-safe sandwich packaging.
Sandwiches, wraps, and paninis need packaging that holds a fold together without crushing the filling or letting condiments leak through. Custom Sandwich Boxes from Prime Custom Packaging give delis, cafes, and quick-service restaurants a grease-resistant, fold-over format built specifically for handheld sandwich service across the United States. Whether the order is a cold sub, a toasted panini, or a wrapped tortilla, the structure keeps the filling contained from counter to first bite.
Every box is produced to the exact dimensions a sandwich needs, printed with a business’s own artwork, and shipped free nationwide with zero minimum order quantity, so a single deli testing a new format and a regional chain running weekly production both move through the same simple process.
A loose wrapper or an oversized box lets a sandwich shift, unfold, or lose its stack during transport. Custom Sandwich Boxes solve that with a snug fold-over or hinged-tray structure sized to the sandwich’s actual footprint, keeping fillings, sauces, and toppings exactly where they were assembled.
Food-safe kraft wrap gives a breathable, grease-resistant barrier for cold subs and wraps, while a coated SBS board handles hot paninis where oil and cheese contact is heavier. The table below breaks down the core construction options used across the line. Businesses comparing construction options often start with Custom Burger Boxes before finalizing a full order.
| Material | Typical Weight | Grease Resistance | Heat Tolerance | Best For |
| Food-safe kraft wrap | Medium weight, flexible | Moderate, absorbent-resistant | Good, breathable | Cold subs and wrapped sandwiches |
| Grease-resistant SBS board | 14pt to 16pt | High, coated surface | Good for short hot contact | Toasted paninis and melts |
| Laminated poly-coated board | 16pt to 18pt | Very high, sealed barrier | Excellent, holds heat longer | Extended-hold delivery orders |
| Corrugated hinged tray | Lightweight, high crush strength | Moderate with liner | Good, vents heat well | Larger or stacked sandwiches |
Different sandwich formats need different mechanics. A cold sub needs a simple fold-over wrap that seals without extra hardware, while a hot panini needs a hinged tray that vents steam without going soggy. Wraps and burritos benefit from a snug foil-lined pouch that holds their shape. The comparison below lines up the variants used across the category.
| Variant | Core Structure | Best For | Closure Type | Standout Feature |
| Fold-over wrap | Flat kraft sheet, tuck fold | Cold subs and deli sandwiches | Tape-free tuck seal | Fast, low-cost assembly |
| Hinged tray box | Shallow hinged clamshell | Toasted paninis and melts | Front lock tab | Vents steam without sogginess |
| Foil-lined wrap pouch | Flexible foil-lined sheet | Wraps, burritos, and rolled sandwiches | Fold-and-tuck seal | Holds rolled shape and heat |
| Compartment box | Divided interior tray | Sandwich plus side combo | Tuck-lock lid | Keeps sides separate from sandwich |
Full CMYK printing reproduces a deli or restaurant’s logo and menu graphics directly onto the wrap or box surface with consistent color across every run. Pantone spot-color matching keeps a brand’s exact palette accurate whether the order is a single location or a multi-unit chain.
Grease-resistant coatings protect printed graphics from oil and sauce contact without dulling the artwork. Matte finishes give a clean, understated look for deli branding, while gloss finishes add shine for bold, color-forward quick-service brands. Restaurants building a complete counter lineup often pair this format with French Fry Boxes to round out a complete menu lineup.
Single-serve formats fit one sandwich, wrap, or panini for grab-and-go counters. Combo formats hold a sandwich plus a side for standard meal orders. Bulk formats support catering and office lunch orders. The table below gives typical dimension ranges so an order can be sized correctly before production begins.
| Size Category | Typical Dimensions | Common Contents | Order Volume | Notes |
| Single-serve wrap | 8 x 5 in flat sheet | One wrap or rolled sandwich | Individual counter orders | Folds to fit handheld size |
| Standard sandwich box | 6 x 5 x 2.5 in | One sub or panini | Typical deli and cafe orders | Most common quick-service size |
| Combo compartment box | 8 x 6 x 3 in | Sandwich plus a side | Standard meal combo orders | Divided interior tray |
| Bulk and catering | 12 x 10 x 4 in and up | Multiple sandwiches per box | Catering and office lunch orders | Reinforced base for stacking |
Tape-free tuck seals keep fold-over wraps closed without added hardware. Front lock tabs secure hinged trays during handoff. Foil lining on wrap pouches holds heat and rolled shape longer. Fold-flat construction lets empty stock store compactly between rushes.
Delis and sandwich shops rely on fold-over wraps and standard boxes for daily counter service. Cafes and coffee shops lean on this format for grab-and-go pairings with drinks and pastries. Catering companies and office lunch providers depend on bulk formats built for multi-sandwich orders. Businesses rounding out a full menu lineup often add Custom Takeout Boxes to their counter lineup.
Deli chains and franchises scaling across multiple locations can standardize one dieline across every unit, keeping branding identical whether an order ships to one location or dozens. Private label operators can pair unbranded stock formats with faster turnaround between menu changes.
A single sample batch and a full wholesale production run both move through the same streamlined process. There is zero minimum order quantity, so testing Custom Sandwich Boxes before a menu launch costs nothing extra upfront, and every order ships free across the United States regardless of size.
Our in-house design team builds a free dieline and mockup for every order, showing exact proportions and fold mechanics before production starts. Revisions continue at no charge until the proof matches a brand’s menu identity.
Every production run passes through a fold and seal check confirming the wrap or box closes cleanly without gaps. Color proofs are compared against approved Pantone references, and grease-resistance is verified through timed contact testing.
| Check | What We Verify | Why It Matters | Method |
| Fold and seal accuracy | Wrap or box closes cleanly without gaps | Keeps fillings contained through handling | Physical sample audit |
| Grease resistance | Coating performance against oil and sauce contact | Keeps packaging intact through service | Timed contact testing |
| Color accuracy | Print output matched to Pantone reference | Keeps branding consistent order to order | Spectrophotometer comparison |
| Heat retention | Foil lining and coating performance under heat | Keeps hot sandwiches warm through delivery | Timed temperature testing |
From delis and cafes in California and New York to catering companies in Texas, Ohio, and the Southeast, Prime Custom Packaging ships Custom Sandwich Boxes nationwide with no regional surcharge, at the same production quality and turnaround in every state.
Whether the need is a single sample batch for a new menu item or a full wholesale production run, Custom Sandwich Boxes from Prime Custom Packaging deliver a grease-resistant, fold-secure format and sharp branding at a cost that works for growing delis and restaurants.
Order Now or email sales@primecustompackaging.com or call +1 (855) 611-8876 for a free quote today.
| Box Style | Custom Sandwich Boxes |
| Dimension (L + W + H) | All Custom Sizes & Shapes |
| Quantities | No Minimum Order Required |
| Paper Stock | 10pt to 28pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Cardstock |
| Printing | No Printing, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors |
| Finishing | Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV, Spot UV, Embossing, Foiling |
| Included Options | Die Cutting, Gluing, Scored, Perforation |
| Additional Options | Eco-Friendly, Recycled Boxes, Biodegradable |
| Proof | Flat View, 3D Mock-up, Physical Sampling (On request) |
| Turnaround | 4 – 8 Business Days, RUSH |
| Shipping | FLAT |
