Rigid gift boxes
Lid-and-base boxes with die-cut inserts for single mugs and two-cup sets. MOQ 300 pcs, 7–15 days.
View gift boxesInternal dimensions by mug size and pack format
Mug Box Sizes Chart
An 11 oz mug with handle needs an internal box of 12.0 × 9.0 × 10.0 cm; a 15 oz mug 13.0 × 9.5 × 11.5 cm; a 20 oz mug 14.0 × 10.5 × 13.5 cm. Two 11 oz mugs in a gift set need 24.0 × 9.5 × 10.5 cm. Each adds 30–37 mm on the handle side, 6 mm to the body diameter and 5 mm to the height.
Jump to the size table
Mug box size chart
All figures are internal dimensions in centimetres, measured length × width × depth. Length runs along the handle axis; width is the body diameter axis. Mug height excludes the handle and includes the rim.
| Mug format | Body OD × height | Units | Minimum internal size (L × W × D) | Suggested pack |
|---|---|---|---|---|
| 11 oz / 330 ml | 85 mm × 95 mm, 25 mm handle | 1 | 12.0 × 9.0 × 10.0 cm | Folding box with die-cut insert |
| 15 oz / 440 ml | 90 mm × 110 mm, 30 mm handle | 1 | 13.0 × 9.5 × 11.5 cm | Rigid box, card or foam insert |
| 20 oz / 590 ml | 98 mm × 130 mm, 32 mm handle | 1 | 14.0 × 10.5 × 13.5 cm | Rigid box with moulded tray |
| Two 11 oz gift set | 2 × 85 mm × 95 mm | 2 | 24.0 × 9.5 × 10.5 cm | Rigid box, handles facing out |
| Two 15 oz gift set | 2 × 90 mm × 110 mm | 2 | 26.0 × 9.5 × 11.5 cm | Rigid box with two-part insert |
| Two 20 oz gift set | 2 × 98 mm × 130 mm | 2 | 28.0 × 10.5 × 13.5 cm | Rigid box, reinforced base |
| 12 oz tumbler | 75 mm × 150 mm, no handle | 1 | 8.0 × 8.0 × 16.0 cm | Folding box with top and base pads |
| 20 oz tumbler | 80 mm × 200 mm, no handle | 1 | 8.5 × 8.5 × 21.0 cm | Rigid tube or tall folding box |
| 11 oz in corrugated mailer | Retail box 12 × 9 × 10 cm | 1 | 15.0 × 12.0 × 13.0 cm (mailer) | Single-wall mailer, 15 mm clearance |
Three constraints decide the size:
- Handle allowance: 30–37 mm on one axis. Handle projection is 25–32 mm, plus a 5 mm buffer. The opposite axis keeps the body diameter plus 6 mm.
- Rim flange and depth: 6 mm and 5 mm. The rim sits 2–3 mm proud of the body, so add 3 mm per side; depth needs 2 mm base clearance and 3 mm lid clearance.
- Packed weight: 11 oz ≈ 0.55 kg, 20 oz ≈ 0.95 kg. A two-mug gift set reaches about 1.9 kg, so use 1,000 gsm board or above and a reinforced base panel.
How the internal size is calculated
The mug is not a box-shaped object: the handle makes one axis longer, and the rim makes the diameter slightly larger than the body. Measure the body outside diameter, the handle projection and the height separately, then add each allowance once.
box_L = mug_OD + handle_projection + 2 × 5 mm buffer
box_W = mug_OD + 2 × 3 mm (rim flange and board)
box_D = mug_H + 2 mm base + 3 mm lid recess
two_mug_L = 2 × (mug_OD + handle_projection) + 20 mm divider and edge clearance
two_mug_W = mug_OD + 6 mm
two_mug_D = mug_H + 5 mm
mailer_L = retail_box_internal_L + 2 × 15 mm (single-wall corrugated)
mailer_L = retail_box_internal_L + 2 × 20 mm (double-wall corrugated)
Worked example for an 11 oz mug: 85 + 25 + 10 = 120 mm length, 85 + 6 = 91 mm width, and 95 + 5 = 100 mm depth. That is 12.0 × 9.0 × 10.0 cm.
Handle and rim allowances
- Handle projection varies by shape. A straight-sided mug projects 25 mm; a wide-loop or ear handle projects 30–32 mm. Measure the widest point, not the handle root.
- Handles need air, not compression. A 5 mm gap on the handle side stops the insert from pressing the handle against the box wall, which is where chips start.
- The rim flange is small but real. A rolled rim adds 2–3 mm to the diameter; a 3 mm per-side allowance also covers board thickness and wrap.
- Depth is a pad decision. A 2 mm base clearance is enough for a folding box; a rigid gift box with a foam insert needs 3 mm of base and 3 mm of lid recess.
- Tumblers drop the handle allowance. A no-handle tumbler only needs 6 mm on each axis, but a tall body needs 5 mm at the top and bottom so the lid does not sit on the rim.
Do not centre the mug in the box. An 11 oz mug with a 25 mm handle is asymmetric: the handle side needs 30 mm while the opposite side needs 5 mm. Centring it wastes 12 mm of length and makes the insert fit loose.
Corrugated mailer or rigid gift box
The choice depends on where the mug is sold, not on the mug size. The retail box internal size stays the same; only the outer protection changes.
- Rigid gift box. 1.5–2 mm grey board walls with a die-cut card or foam insert. Best for retail shelves, two-cup gift sets and mugs sold with a matching card or coaster. Unit cost is higher and the box ships assembled.
- Corrugated mailer. Single-wall or double-wall board with 15–20 mm clearance around the retail box. Best for ecommerce and drop-ship, because it ships flat and absorbs the drop. A 20 mm clearance is the safer choice for a 20 oz mug.
For an 11 oz mug the retail box is 12.0 × 9.0 × 10.0 cm internal; a single-wall mailer around it needs 15.0 × 12.0 × 13.0 cm internal. A double-wall mailer needs another 10 mm on each dimension. Compare formats on the gift boxes and folding boxes pages.
Transit and carton planning
Ceramic mugs fail at the handle and the rim, so the insert and outer carton matter as much as the internal size.
- Insert support. The insert should contact the body, not the handle; a 1 mm gap at the handle is better than direct pressure.
- Carton count. A 60 × 40 × 40 cm export carton holds about 36 single 11 oz boxes in two layers, or 12 two-cup gift sets.
- Board weight. 500–2000 gsm covers folding and rigid construction; use 1,000 gsm or above for two-mug sets and 20 oz singles.
We coordinate with specialized converting partners on insert tooling and board weight, and confirm the packed fit on a physical sample. Free samples, a 24-hour quote and worldwide shipping apply to every format here.
Related packaging
Folding boxes
Flat-shipping retail boxes for 11–15 oz mugs and ecommerce runs. Board 500–2000 gsm.
View folding boxes
Printed packaging range
Mug boxes, mailers and inserts quoted as one packed set with a single size drawing.
View packaging productsRelated sizing charts
- Gift box sizes chart — jewellery, candles, mugs, chocolate and hampers.
- Perfume box sizes chart — 30–200 ml bottles with insert allowance.
- Mailer box size chart — outer transit cartons and volumetric weight.
- Candle box sizes chart — 100 g to 1 kg candle jars and gift sets.
- Chocolate box sizes chart — bars, truffles, pralines and heart boxes.
Frequently asked questions
What size box fits an 11 oz mug?
An 11 oz mug with an 85 mm body and 25 mm handle projection needs 12.0 × 9.0 × 10.0 cm internal. The handle side gets 35 mm of combined allowance, the body 6 mm for the rim flange, and the height 5 mm for base and lid clearance.
How much extra width does a mug handle need?
Allow 25–32 mm for the handle projection plus a 5 mm buffer on the handle side, so 30–37 mm added to the body diameter on that axis. The other axis needs only 6 mm for the rim flange and board.
Should a mug ship in a corrugated mailer or a rigid gift box?
A rigid gift box with a die-cut insert suits retail and gifting, while a corrugated mailer with 15 mm clearance per side suits ecommerce. Both use 500–2000 gsm board, and a two-mug set needs a reinforced base at 1,000 gsm or above.
What is the minimum order and lead time?
Custom mug boxes start at 300 pcs, or 500 pcs for custom molds or irregular shapes. Lead time is 7–15 days after artwork approval, with free samples, a 24-hour quote and worldwide shipping. Board weight is 500–2000 gsm.
Send the mug, not just the volume.
Tell us the body diameter, handle projection, height and pack format. We reply within 24 hours with an internal size recommendation and a packed quote.