Strong
Corrugated Cardboard
Fluted middle layer for strength and cushioning. Ideal for mailer boxes, shipper cartons, and any product that needs extra protection during delivery.
Trusted by UK businesses
UK Packaging Specialists
Low MOQ
Fast Turnaround
Estimated price
£0.10 – £1.10
Final price depends on material, size & quantity
Custom Popcorn Boxes
★★★★★
4.5/5
15+ reviews
Verified on Trustpilot
Bestseller
Packaging Supplier
Whether it’s the smell of fresh popcorn at a cinema, the excitement of a school fundraiser, or the nostalgia of a funfair, packaging plays a bigger role than most people realise. Our custom popcorn boxes aren’t just containers — they set the tone before the first bite. A sturdy, well-designed popcorn box protects your product, makes serving easy, and becomes part of the experience. With Healey Packaging, you’re not buying “just a box” — you’re investing in a piece of branding your customers will hold onto from the first handful to the last.
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1 Box Style
2 Material
3 Quantity
4 Contact
ISO Certified
FSC® Certified
Food Safe Materials
UK Based Manufacturing
Low Minimum Orders
Explore Our Premium Packaging Options
Mix and match materials, printing methods, inks, finishes, and add-ons to build packaging that feels completely on-brand. Start with the material, then move through print and finishing to see what fits your product best.
Eco
Natural Brown Kraft
Rustic, uncoated look that feels honest and sustainable. Great for bakery, subscription boxes, and earthy lifestyle brands that want a natural tone.
Premium
SBS / Bleach Card
Bright white, smooth surface for sharp printing and rich colors. Perfect for cosmetic cartons, medicine boxes, and premium retail packaging.
Luxury
Black Kraft / Black Card
Deep matte black stock that pairs beautifully with metallic foil. Best for luxury rigid boxes, apparel packaging, and special gift sets.
Flexible
Digital Print
Great for smaller quantities, seasonal packaging, or designs that change often. Fast setup with strong color output and no plate costs.
Classic
Offset Print
Industry standard for high-volume packaging. Ideal when you need consistent Pantone colors and the most economical cost per unit at scale.
Spot effects
Scodix Enhancement
Digital enhancement that adds raised UV, textures, and metallic-style effects to selected areas, creating a premium, touchable finish.
Gloss
UV Print
Cured with UV light for instant drying and strong color density. Works well when you need vibrant prints on coated boards.
Standard
CMYK Process Inks
Ideal for photography, gradients, and detailed artwork. Most packaging projects start here before adding special colors or finishes.
Branding
Pantone Spot Inks
Used when color accuracy is critical. Pantone inks lock in signature brand colors across different print runs and materials.
Bold
Screen Printing
Screen printing lays down a thicker layer of ink, creating vibrant solid colors and strong opacity. Best for bold logos, solid shapes, and designs that must pop even on darker materials.
Eco
Soy / Vegetable Inks
Lower-VOC options that support more sustainable packaging. Often paired with kraft stocks and minimalist designs.
Matte
Matte Lamination
Gives packaging a smooth, elegant feel with reduced shine. A favourite for luxury, cosmetic, and tech products.
Gloss
Gloss Lamination
Adds shine and extra ink protection. Works well for bold colors, retail shelves, and youth-focused brands.
Tactile
Soft-Touch Coating
Creates a velvety, rubberised feel that makes customers want to hold the box longer. Ideal for high-end unboxing experiences.
Highlight
Spot Gloss UV
High-gloss UV applied only to selected areas like logos or patterns, so they catch the light without making the whole box shiny.
Luxury
Foil Stamping
Metallic foil pressed into the board for instant shelf impact. Great for logos, borders, and badges on gift, cosmetic, and rigid boxes.
Raised
Embossing
Embossing lifts selected artwork from the surface, giving logos, patterns, and brand marks a premium 3D raised effect that customers can feel instantly.
Depth
Debossing
Debossing presses artwork into the board, forming an elegant recessed impression. Works beautifully for minimalist luxury packaging and fine-detail branding.
Windows
Die-Cut Windows
Custom window shapes let customers see the product before they buy. Can be left open or backed with clear PET where needed.
The Greasy, Crumbly Truth About Popcorn Boxes
Look, popcorn is a nightmare to package. It’s fragile, greasy, and the second a box fails, you’ve got a customer with a handful of crumbs and a terrible last impression of your brand. We’ve seen it all – split seams, soggy bottoms, boxes that can’t even survive a short walk from the concession stand.
That’s why we build our boxes to handle the job. It’s not just cardboard; it’s a calculated mix of rigidity and feel. We spec materials that fight grease and construction that prevents blowouts. Whether you need tiny individual-serving boxes or giant branded theatre boxes, the goal is the same: your popcorn arrives intact, fresh, and ready to enjoy, not clean up.
Why Your Best Marketing is a Handheld Billboard?
A box of popcorn is often shared, photographed, and carried around for longer than most snacks. That makes it prime real estate for your branding. We offer custom printed popcorn boxes with:
- Full-colour graphics using CMYK or Pantone printing
- Special finishes like matte, gloss, or soft-touch lamination
- Foil stamping and spot UV for logos or promotional campaigns
- Die-cut shapes and popcorn box templates for unique looks
From pink popcorn boxes for themed events to branded popcorn boxes for national chains, we’ll help your packaging reflect the personality of your business.
Trusted by Cinemas, Fundraisers, and Celebrations Nationwide
Over more than a decade, we’ve produced millions of boxes for clients ranging from independent shops to large-scale venues. Some of the most common uses include:
- Cinemas and theatres serving popcorn in branded packaging
- Schools and charities using mini popcorn boxes for fundraisers
- Weddings and private events where personalised popcorn boxes act as favours
- Street food vendors and stalls using custom popcorn boxes to stand out
- Retailers selling pre-packed snacks in popcorn box packaging with food-safe coatings
Protecting Quality While Enhancing Experience
The real challenge with popcorn packaging is keeping it fresh without losing the sensory appeal of “popcorn in a box.” We use food-grade, grease-resistant boards that stop oil stains from leaking through, keeping the box looking neat from start to finish.
Our boxes are easy to assemble, stack neatly in storage, and provide a reliable structure for serving both sweet and salted popcorn. Whether you’re supplying a single kiosk or a chain of cinemas, you’ll have packaging that holds up under pressure.
Sustainable Choices for Modern Brands
More customers are asking for eco-friendly options, and we make it simple to say yes. We offer:
- Recyclable and compostable cardboard popcorn boxes
- FSC®-certified stocks for responsible sourcing
- Biodegradable coatings that maintain grease resistance without plastics
By choosing sustainable popcorn packaging, you meet customer expectations and reduce environmental impact — without compromising durability.
Custom Popcorn Box Sizes and Styles
Every serving style calls for a different solution, which is why we don’t just offer one-size-fits-all. Options include:
- Mini popcorn boxes for individual portions
- Large takeaway popcorn boxes for family sharing
- Custom tray-and-sleeve style popcorn packaging for retail shelves
- Cardboard popcorn boxes with lids to keep contents sealed until serving
If you have a popcorn box design in mind, we’ll create a dieline template to match your exact requirements.
More Than a Supplier: Your Packaging Partner
With more than ten years in the packaging industry and trusted by 1,000+ UK brands, Healey Packaging has built a reputation for reliability. Unlike off-the-shelf suppliers, we control the process from design to delivery. That means:
- Consistent quality, box after box
- Scalable production runs (from 100 to 100,000+)
- Flexible lead times for seasonal demand
- UK and international shipping
- Prototypes available before bulk production
When you partner with Healey Packaging, you get more than a manufacturer — you get a packaging partner who understands how presentation drives sales.
| Dimension (L + W + H) | All Custom Sizes & Shapes |
|---|---|
| Quantities | No Minimum Order Required |
| Paper Stock | 210gsm, 250gsm, 280gsm, 300gsm, 350gsm, 420gsm, 460gsm, 500gsm, Bleach Card (SBS), Eco-Friendly Kraft, E-flute Corrugated, Bux Board, etc. |
| 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, Scoring, Perforation |
| Additional Options | Eco-Friendly, Recycled Boxes, Biodegradable |
| Proof | Flat View, 3D Mock-up, Physical Sampling (On request) |
| Turnaround | 7 – 10 Business Days, RUSH |
| Shipping | FLAT |
Can I order personalised popcorn boxes for small events like weddings?
Yes — we cater for both small runs and bulk orders. Many clients order custom made popcorn boxes for weddings, birthdays, and private parties.
Will these boxes get soggy with hot, buttered popcorn?
Guaranteed. We use a special food-safe board that's designed to block grease and oil, so the box stays rigid and your customer's hands stay clean.
Can you match brand colours exactly?
Yes — we use Pantone matching alongside CMYK printing to ensure your brand colours stay consistent across every batch.
Do you ship popcorn packaging internationally?
We do. While most of our orders are UK-based, we also deliver across Europe and beyond.
Why Brands Trust Us
We are not just box manufacturers. We help brands package smarter, ship safer, and sell better, without unnecessary complexity.
- Packaging Specialists Industry-focused structures, not generic templates.
- Low MOQ Support Start small, scale confidently.
- Material-First Engineering Right board, right strength, right finish.
- UK & Global Fulfilment Flat packed, secure, and delivery-ready.
Our Process
01
Share your product size, quantity, and use-case.
02
We recommend structure, material, and finish.
03
Approve dieline or sample before production.
04
Manufacturing, quality check, and delivery.
