Branded Snack Boxes That Stand Out
A custom Lays box is a fun, high-impact packaging format that puts your brand on one of the most recognisable snack product shapes in the world. Brands use Lays-style chip box packaging for promotional campaigns, event giveaways, subscription box inserts, retail novelty products, and custom-branded snack gifting. At Teal Packaging, we produce custom Lays boxes in a range of sizes and finishes with a 2-week turnaround, a minimum order of 50 units, and Free shipping is included on every Teal order, with delivery details confirmed during quoting.
Our manufacturing partners are experienced in producing branded snack box formats that replicate the structural proportions of standard chip packaging in premium paperboard constructions. Free design support is included, covering artwork layout, typography, and full-colour proofing before any production begins. Whether you are creating a novelty gift, a promotional campaign piece, or a branded snack product, a custom chip-style box is a packaging format that creates genuine excitement.
For additional creative packaging formats that work alongside novelty snack boxes, explore our custom retail boxes and custom display boxes.
Materials and GSM Specifications
A custom Lays box needs to be lightweight enough to feel authentic, rigid enough to hold its shape on shelf, and printable across a large surface area with vibrant, high-resolution graphics. Material options include:
- 250 GSM SBS (Solid Bleached Sulfate) Board: A smooth white coated board that delivers the brightest, most colour-accurate print results. Ideal for designs that replicate the vivid, full-bleed look of commercial chip packaging. Lightweight and easy to form into the tapered chip box structure.
- 300 GSM SBS Board: A slightly heavier white board option that adds rigidity to the box structure while maintaining excellent print quality. Recommended for boxes that will be handled frequently or displayed in a retail setting.
- 250 GSM Kraft Board: For brands that want a natural, eco-friendly aesthetic for their branded chip box, kraft board provides a warm, earthy background that pairs well with two-colour or spot-colour print designs.
- 300 GSM Kraft Board: A heavier kraft option for premium novelty snack boxes where the natural material aesthetic is part of the brand story.
FSC-certified paper options are available by specification. Soy-based inks are used across all print runs. Finished boxes are recyclable through standard paper recycling streams.
Customization Options
The large, curved surface of a custom Lays-style box is a creative canvas for brand expression. Customization options include:
- Printing: Full-colour CMYK printing with photographic imagery, bold brand graphics, and fine text across the full surface of the box. Pantone-matched colours available for precise brand colour reproduction.
- Finishes: Gloss lamination for maximum colour vibrancy; matte lamination for a premium, tactile result; uncoated SBS or kraft for a natural, minimal look.
- Foil Stamping: Metallic foil on logos and key design elements for premium novelty boxes and corporate branded gifting.
- Custom Typography: Parody, personalised, or event-specific text incorporated into the chip box label design to create a truly one-of-a-kind product.
- Food Safe Interior Lining: For boxes intended to contain actual food products, a food-safe PE liner or kraft interior liner can be applied to the inner surfaces.
- Custom Closure Styles: Standard tuck top, sealed top, or open top formats depending on product and display requirements.
Our design team has experience creating layouts that reference the visual language of classic snack packaging while incorporating your brand identity. Share your creative brief and we will prepare a proof that captures the fun and personality of the format.
Available Sizes
Common sizes for custom Lays boxes are proportioned to match the visual familiarity of standard chip packaging while accommodating a range of product contents:
- 3 x 2 x 7 inches - a small individual-serve chip box format for novelty gifts and event favours
- 4 x 3 x 9 inches - the standard single-serve size most closely matching a regular-size chip bag footprint in box form
- 5 x 3.5 x 10 inches - a slightly larger format for subscription box inserts and promotional giveaways with more content volume
- 6 x 4 x 11 inches - a family-size chip box format for larger gifts, event packages, and multi-product inserts
- 7 x 5 x 12 inches - an oversized format for novelty display pieces, party favours, and large promotional campaigns
If your concept requires a specific footprint or height that differs from standard chip packaging proportions, share your requirements and our team will engineer a custom dieline to your specifications.
Sustainability Commitment
Teal Packaging produces custom Lays boxes from FSC-certified paper options materials using soy-based inks across all print runs. Unlike foil-laminated flexible chip bags, which are difficult to recycle, our paperboard chip box format is recyclable through standard paper recycling programs and compostable in home composting environments when finished without plastic lamination.
For brands creating novelty or promotional packaging, choosing a paperboard chip box format over a foil pouch alternative is a meaningful sustainability upgrade that also communicates brand responsibility to recipients.
Our kraft board options take this a step further, offering a fully natural material story that pairs beautifully with eco-conscious brand positioning.
Pair your custom chip boxes with sustainable filler materials such as our custom kraft boxes or tissue paper liners to build a complete eco-friendly gifting or promotional packaging program.
How to Order
Ordering a custom Lays box from Teal Packaging is a straightforward four-step process:
- Step 1 - Request a Quote: Submit your box dimensions, material preference, finish type, quantity, and design concept through our quote form. We will respond within one business day.
- Step 2 - Design and Proof: Our design team will prepare the structural dieline and create a full-colour digital proof showing your artwork on the chip box format. Revisions are included.
- Step 3 - Confirm Your Order: Approve the proof, confirm your order details, and complete payment to enter production scheduling.
- Step 4 - Production and Shipping: Orders are completed within 2 weeks and shipped free to US, Canadian, UK, and Australian addresses.
The minimum order quantity is 50 units per design. For event campaigns or promotional runs requiring multiple designs, each design is subject to its own 50-unit minimum. Contact our team for guidance on multi-design orders.
