Custom Vape Boxes

Vape Product Format Determines the Box Specification - and UK Regulation Determines What Must Appear on It 

Aly Packaging manufactures custom vape boxes for UK e-liquid brands, pod system manufacturers, cartridge producers, and vape kit retailers. Two decisions shape every vape box brief. The first is the product format: a pod cartridge, an e-liquid bottle, and a rechargeable kit all have different dimensions, insert requirements, and closure specifications that must be established before board weight or finish is discussed. The second is regulatory compliance: nicotine-containing vape products sold in the UK are subject to the Tobacco and Related Products Regulations 2016, which impose specific mandatory labelling requirements on the outer packaging. We address both before production begins. 

UK Tobacco and Related Products Regulations: What Must Appear on Custom Vape Boxes for Nicotine Products 

Custom vape boxes containing or associated with nicotine-containing e-liquids must comply with the UK Tobacco and Related Products Regulations 2016 (TRPR). Mandatory requirements on the outer packaging include a health warning covering 30 per cent of the two largest surfaces stating the product contains nicotine, which is a highly addictive substance; a nicotine concentration statement; an ingredients list; a leaflet reference; and manufacturer details. Child-resistant closure or child-resistant packaging is also required for nicotine-containing e-liquids. Aly Packaging designs vape boxes with all mandatory TRPR label panels built into the dieline before any brand design elements are placed. 

Why Choose Aly Packaging as Your Vape Boxes Supplier in the UK?

At Aly Packaging, delivering premium packaging is second nature to us. With over 15 years of industry expertise, we go beyond the standard to offer exceptional packaging solutions that enhance product presentation and brand identity. Every box we create is crafted with precision, ensuring quality that aligns perfectly with our clients' vision. Our dedication to excellence drives us to deliver packaging solutions that truly stand out in the market. Explore our range of top quality packaging options, including custom rigid boxes, eco-friendly boxes, and kraft boxes, all designed to add sophistication and durability to your product packaging. The UK ban on single-use disposable vapes, effective June 2025, has materially changed the commercial landscape for vape packaging. Brands that previously sold large volumes of disposable products now need packaging for rechargeable pod systems, refillable kits, and e-liquid bottles - all of which have different box specifications from the single-piece disposable. Pod systems need an insert that holds the device and the pod separately. Refillable kits need a multi-compartment configuration. E-liquid bottles need the height clearance and child-resistant outer packaging that the TRPR requires. We specify each of these as distinct product briefs rather than as variations of the same box. 

Additional Benefits We Offer

We supply custom vape boxes from low minimum quantities, making TRPR-compliant professionally manufactured packaging accessible for independent e-liquid brands and small vape retailers as well as larger manufacturers running volume programmes. Standard turnaround is 10 to 12 business days from artwork approval, with a rush option in 6 to 8 business days. Free digital proofs and prototype sampling are available before any production run, so you can confirm TRPR label panel positioning, insert configuration, and child-resistant closure compatibility before committing to a full order. 

Achieving Unparalleled Visual Appeal With Unique Add ons!

When it comes to gaining customer attention, the physical appearance of the box needs to be flawless. We acknowledge this and perfect our packaging design with our sophisticated finishes. Our experts closely collaborate with every customer to understand their brands' design requirements and use their skillfulness to derive a unique solution. We understand that designing needs variation to create brand differentiation. To achieve this, we offer a variety of add-ons to our clients that are customised to their unique requirements. Our exclusive variety includes metallic foil stamping, holographic printing, embossing/debossing, UV spot printing, and many more options that offer individual appeal.

Contact Us to Place Your Orders Today!

Aly Packaging UK manufactures custom vape boxes for e-liquid brands, pod system manufacturers, cartridge producers, and vape kit retailers across the UK. Whether you need mandatory TRPR health warning and nicotine declaration panels built into the dieline before design begins, insert configuration specified for a rechargeable kit or pod system, child-resistant outer packaging for nicotine-containing e-liquids, or low minimum quantities for a new product following the UK disposable vape ban, we work through every compliance and structural decision before production begins. Contact us at sales@alypackaging.co.uk or call 07462 212 450.