Designing vape packaging can eat up a great deal of resources, so it’s best to get it right from the start. This process involves many stages and considerations related to materials, printing methods, layout details, compliance, brand identity features, special add-ons, and sustainability options.
Here’s what you must know to bring the packaging creation process for your vapes to fruition and determine when you should go custom or adopt standard solutions.
Pick materials
Cardboard boxes
Use high-density cardboard for a sturdy feel. Thickness can be around 18-24 pt for a premium impression while preventing crushing and protecting delicate vaping devices.
Plastic clamshells or blister packs
Thicker PET or PVC plastic (0.3-0.5 mm) works well. Add a backing card with product details. Keep in mind that plastic is affordable and common, but it often looks generic.
Metal tins or tubes
Select a tin design with a snug lid. Add a thin foam layer inside to keep vapes from rattling. Metal tubes are great for tubular devices.
Vape pouches
Opt for laminated material that blocks light and oxygen. Its thickness should be around 70-90 μm. Consider a tear notch or a resealable zipper for every vape pouch.
Choose printing methods
Offset printing
You’re good to go with CMYK or Pantone inks. You can add a matte or soft-touch laminate for a smooth feel that is unaffected by smudges.
Digital printing
This printing method is more flexible. The quality is slightly lower than offset, but it takes less time to render things onto a package. It’s suitable for limited editions or custom disposable vape packaging when you often need to update flavor or strain information.
Hot foil stamping
You can revamp a foil-style logo for a high-end touch. Gold or silver foil on a matte black box has enormous attention-grabbing power. Limit foil stamping to key elements, like your brand name.
Embossing or debossing
Raise or press your logo to create a tactile feel. It should highlight your brand, not overwhelm the package.
Keep the layout and graphics clear
Front
Show your brand logo at the top. If it is cannabis vape packaging, clearly list THC/CBD content. Keep text large enough to read at arm’s length. Use a sans-serif font, at least 10-12 pt, on a contrasting background.
Right and left sides
Use one side for flavor or strain details, like “Banana Cream Kush, Indica.” On the other side, place a QR code linking to lab tests or instructions. Make sure the QR code is at least 1 inch.
Back
Place the required warnings and ingredient lists. For disposable vape packaging, include clear usage instructions, like “Remove the cap to inhale. Dispose after the battery is depleted.” Add a short brand story or a hotline number for support. Keep regulatory text at least 8 pt.
Color scheme
Limit yourself to 2-3 main colors. If you sell fruity flavors, showcase a small fruit icon. If you want a natural vibe for cannabis vape packaging, stick to muted greens or earthy tones.
Fulfill compliance requirements
Child-resistant features
If it is a legal requirement, pick a box with a certified child-resistant mechanism. For vaping devices, it can be a push-and-turn cap or a sealed blister pack that requires scissors to access.
Warning labels
You should always follow local cannabinoid symbols or text guidelines. Place warnings on the main display side or on a bright background to ensure visibility.
Ingredient lists
Show THC and CBD percentages in bold. People only want accurate information, so you need to be factual and precise.
Spruce up your branding
Consistent logo placement
Position your logo in the same spot on custom vape packaging for all your products. The top center on the front is a standard option.
Unique finishes
If your brand aims for luxury, matte black with a subtle foil logo might work. If your brand focuses on health and wellness, pick pastel colors and a leaf motif. If you sell cutting-edge vape tech, use a minimalist white box with a single accent color.
Flavors
Alter a small element per flavor or strain. For instance, it can be a colored stripe at the bottom (green for mint, red for strawberry, and purple for an Indica strain). Keep the rest of the design consistent so customers know it’s your brand.
Protect the device
Inserts and trays
Use die-cut cardboard or molded pulp inserts to hold vapes. For glass carts, a foam insert with precise cutouts is excellent.
Seals and freshness
A small foil seal or a shrink band can make your vape liquids last longer. For a vape pouch, choose a multi-layer barrier film with aluminum foil inside.
When shipping large volumes
Consider outer cartons sized to carry multiple retail boxes. This reduces movement and lowers damage rates during transport.
Aim for sustainability
Recycled cardboard
Many buyers prefer eco-friendly materials. Choose an FSC-certified paperboard. Mention “Printed on recycled paper” near the barcode.
Plastic alternatives
If you have to use plastic, check out PLA-based or hemp-based options. A biodegradable pouch will align with the natural image of your vaping device.
Essentials and final checks
Your vape packaging should include:
- Robust container to safeguard the device physically
- Clear brand logo on the front, easy-to-read flavor/strain details, and proper warnings
- Compliant elements for child access control and cannabinoid labeling
- High-quality printing (offset or digital) with a finish that matches your brand image
- Optional features like foil stamping for premium lines
- Simple color scheme and font that looks professional
- Eco-friendly materials and notes about recyclability
Before mass production, it’s an efficient move to order a package sample to check color accuracy, text readability, and fit. Insert your vaping device and shake it gently. Nothing should rattle. Try scanning the QR code on the printed box to make sure it’s valid.
Also, you may need to show the final mock-up to a compliance officer or a lawyer. Make sure all the required warnings, icons, and labels are correct. It’s cheaper to fix this before producing thousands of custom vape packaging units. Make adjustments (if needed) and give your vapes the go-ahead.