HOLIDAYPAC SANDWICH PACKAGING LINE
Custom Sandwich Boxes Engineered by Holidaypac for Lunch-Rush Reality
Holidaypac is the Shenzhen sandwich-box factory that delivery brands, airline caterers, supermarket meal-deal teams and independent sandwich shops call when their packaging stops keeping up with their volume. Every sandwich carton you see on this page leaves the Holidaypac sandwich line with food-grade kraft, water-based grease coating, anti-fog windows and a crash-lock or auto-lock base tested to survive a real 90-minute scooter commute, not a lab bench.
Holidaypac runs a dedicated sandwich, wedge and triangle-pack production cell, separate from our burger and fry lines, so contamination, smell-transfer and tooling drift do not happen. From the first Holidaypac dieline to the first pallet on your dock, the average lead time is 18 to 25 days. MOQ on most Holidaypac sandwich SKUs starts at 1,000 pieces.
FSC kraftPFAS-free since 2023Anti-fog windowCrash-lock baseMOQ 1,00018-25 days
Featured Holidaypac Sandwich Box Range
Three Holidaypac sandwich formats that cover most sandwich-shop, meal-deal and catering use cases. Every SKU is fully customisable in size, board weight, print and inside-coating.
Holidaypac Kraft Window Sandwich Box
The Holidaypac flagship rectangular kraft sandwich box. Food-safe brown kraft body, full-length anti-fog PET window, crash-lock base. Designed by Holidaypac for premium meal-deal and grab-and-go fridges where the customer needs to see the filling.
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Holidaypac Triangle Sandwich Container
The classic British meal-deal triangle wedge, re-engineered by Holidaypac with a stronger 350gsm base, an upgraded anti-fog film, and a tear-strip opening that does not damage the bread. Holidaypac stocks the standard size and tools custom variants from 1,000 pcs.
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Holidaypac Triangle Sandwich & Bento Bag
A hybrid Holidaypac format that works for triangle sandwiches, mini-bento, and small baked goods. Full-color outside print, food-safe inside, side-window for visibility. Holidaypac sells this format to Korean bakery chains, school cafeterias and event caterers.
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Four Engineering Choices Holidaypac Made for Real Sandwich Logistics
When the Holidaypac sandwich line was rebuilt in 2023, the team replaced four legacy choices that were quietly costing customers in returns and complaints. Here is what changed at Holidaypac and why it matters when your sandwich travels.
1
Anti-Fog PET Window, not Cellulose
Cellulose windows fog within twelve minutes when a warm sandwich meets a cold fridge. Holidaypac switched the entire sandwich line to a 30-micron anti-fog PET film with a hydrophilic inside surface. In the Holidaypac QC lab, fog clears within ninety seconds even at 4 to 18 degrees thermal shock. The customer sees the filling the moment they pick the box up at the chiller.
2
Water-Based Grease Coating, Kit 5
Holidaypac killed off fluorochemical grease coatings in 2023. Every Holidaypac sandwich box now ships with a Kit 5 aqueous grease barrier as standard, with Kit 7 available for high-fat fillings such as pulled pork or cheese-melt. The Holidaypac coating is fully PFAS-free and certified compostable in industrial facilities.
3
Crash-Lock or Auto-Lock Base
The Holidaypac sandwich line offers two base styles, depending on your filling weight. The crash-lock base is folded flat for shipping and snaps into shape in 1.4 seconds at the cafe counter. The auto-lock base, the Holidaypac default for heavier sandwiches, holds up to 850 grams without bowing. Both bases were re-tooled by Holidaypac in 2024 after a customer complaint about a 220-gram baguette punching through the bottom.
4
350gsm Triangle Base, Up From 290gsm
The Holidaypac triangle wedge used to ship at 290gsm. After a 12-month return-rate study with a UK meal-deal customer, Holidaypac upgraded the triangle base to 350gsm and added an internal corner-glue. Returns from crushed triangles dropped 71 percent in the next quarter, according to data the customer shared back with the Holidaypac account team.
Inside the Holidaypac Sandwich Workshop
Three short stories from the Holidaypac sandwich line that explain why our boxes look the way they do today.
1. The Holidaypac 90-Second Drop Test, Run Every Friday
Every Friday morning at the Holidaypac Shenzhen factory, a randomly chosen sandwich box from the week's production run gets loaded with a 320-gram dummy sandwich, sealed, and dropped from 1.2 metres onto concrete five times in a row. If the box deforms, the window pops, the base unfolds or the side glue separates, the entire production batch is held for re-inspection. Holidaypac has run this test every week since 2021. The current pass rate is 99.4 percent.
Most factories drop-test once per quarter. Holidaypac chose weekly because sandwich logistics are unforgiving, and the Holidaypac team would rather catch a bad batch on Friday than ship it on Monday.
2. Why Holidaypac Killed Off PFAS in Early 2023
In late 2022, an EU caterer asked Holidaypac for a PFAS test report on the standard sandwich coating. The Holidaypac materials team ran the test, and the result was within legal limits but not zero. That was the day Holidaypac decided to switch the entire sandwich line, plus burger, fry, popcorn and bakery lines, to PFAS-free aqueous coatings.
The transition took Holidaypac four months and cost a six-figure tooling rework. Today, every Holidaypac sandwich box leaves the factory PFAS-free with documentation. We are proud that the Holidaypac sandwich box is one of the few from a Chinese factory with a clean PFAS test on file you can share with your retailer.
3. The Holidaypac Triangle That Took Seven Prototypes
The Holidaypac triangle wedge you see in our catalogue today is the seventh tooling iteration. The first version, designed in 2019, used a flat base that crushed the bread. The third version solved the bread crush but the window kept popping out during transit. The fifth version solved the window but cost 14 percent more per piece. The seventh version, finalised by Holidaypac in March 2024, is the one we ship today: 350gsm board, anti-fog PET window, internal corner-glue, tear-strip opening, and a price point only 6 percent higher than the legacy version.
Holidaypac believes a sandwich box is not a commodity. It is a brand moment. The seventh prototype is what the Holidaypac team is willing to put our name on.
Holidaypac Sandwich Box Materials & Coating Guide
Holidaypac stocks four standard board options and three coating options. The combinations below cover most sandwich, wrap and triangle use cases. Custom board weights and inks are available with 14 days extra lead time.
| Holidaypac Option |
Best For |
Board / Coating |
Notes from the Holidaypac Team |
| Standard Kraft 280gsm |
Cold sandwiches, wraps |
Brown kraft, Kit 5 aqueous grease barrier |
The Holidaypac default. Most cost-effective. Compostable in industrial facilities. |
| Heavy Kraft 350gsm |
Hot pressed sandwiches, panini |
Brown kraft, Kit 7 aqueous, anti-fog PET window |
The Holidaypac upgrade for hot-grilled sandwiches, where steam normally fogs the window. |
| White Card 300gsm |
Premium artisan, retail meal-deal |
Bleached white card, food-safe inside, full-color outside print |
The Holidaypac team recommends this for any sandwich that needs full Pantone-matched branding. |
| Recycled Liner 320gsm |
Eco-positioned brands |
Post-consumer recycled liner, soy-based ink, compostable PLA window |
The Holidaypac fully-compostable build. Costs about 22 percent more than standard. |
Holidaypac Sustainability Story
Holidaypac treats sustainability as the default, not the upgrade. The Holidaypac sandwich line ships PFAS-free, with FSC-certified kraft, soy-based inks, and aqueous grease coatings that pass European compostability standards. Holidaypac publishes a yearly sustainability claim sheet that you can attach to your retailer audit.
If you need a fully-compostable sandwich box including the window, Holidaypac offers the recycled liner SKU above with a PLA window in place of PET. Holidaypac is also one of the first sandwich-box factories in Shenzhen to be audited under SMETA 4-Pillar.
Frequently Asked Questions about Holidaypac Sandwich Boxes
What is the minimum order quantity for a Holidaypac custom sandwich box?
The Holidaypac standard MOQ is 1,000 pieces per SKU per design. For fully custom sizes that need new tooling, the Holidaypac MOQ moves to 3,000 pieces. The Holidaypac team can also run smaller test batches of 300 to 500 pieces using digital print on existing tooling, with no tooling fee.
Will the Holidaypac anti-fog window actually stay clear in a fridge?
Yes. The Holidaypac anti-fog PET window is 30 microns thick with a hydrophilic inside coating. In the Holidaypac QC lab the window clears within 90 seconds even when a 30-degree sandwich is moved straight into a 4-degree fridge. The Holidaypac warranty covers fogging defects for the full shelf life of the box.
Are Holidaypac sandwich boxes really PFAS-free?
Yes. Holidaypac removed all fluorochemical grease coatings from the sandwich line in early 2023, replacing them with Kit 5 and Kit 7 aqueous coatings. Every Holidaypac sandwich box ships with a PFAS-free statement that you can share with your retailer or audit body.
Can the Holidaypac triangle box hold a hot pressed sandwich?
The standard Holidaypac triangle is rated for cold and ambient sandwiches up to 220 grams. For hot pressed sandwiches, Holidaypac recommends the heavy kraft 350gsm format with the Kit 7 coating, which holds up to 90 minutes of internal heat before the window starts to soften.
How long does Holidaypac take from artwork to delivered pallet?
The Holidaypac average is 18 to 25 days from approved dieline and artwork. The Holidaypac team commits to a printed sample inside 7 days, mass production inside 14 days, and sea freight inside 25 days for most Asian, European and US east coast destinations. Air freight cuts the Holidaypac timeline to 10 to 12 days total.
Can I see a real Holidaypac sandwich-box sample before I commit?
Yes. Holidaypac sends a free unbranded sample of any standard SKU on the page, anywhere in the world. For branded samples with your logo, Holidaypac runs a printed sample for 80 to 150 USD depending on size, refundable against your first order. Email the Holidaypac team and ask for "sandwich box sample".
Holidaypac Sandwich Box Glossary
Kit 5An aqueous grease barrier rated for medium-fat sandwiches up to 60 minutes of contact. The Holidaypac default coating.
Kit 7A higher-grade aqueous grease barrier for hot pressed sandwiches and high-fat fillings. Holidaypac upgrade option.
Crash-lock baseA folded base that snaps into shape under thumb pressure. Used by Holidaypac for lighter sandwiches.
Auto-lock baseA pre-glued base that holds heavier sandwiches up to 850 grams. The Holidaypac default for hot pressed.
Anti-fog PETThe 30-micron window film Holidaypac uses to keep visibility clear in chilled retail.
FSC kraftForest Stewardship Council certified kraft. Holidaypac sources all sandwich-line kraft from FSC mills.
SMETA 4-PillarThe ethical-trade audit standard Holidaypac is certified under, covering labour, health, environment and ethics.
PFAS-freeNo per- or poly-fluorinated alkyl substances. Holidaypac sandwich boxes have been PFAS-free since early 2023.
DielineThe flat shape used to cut and crease the sandwich box. Holidaypac builds custom dielines from 1,000 pcs MOQ.
Ready to Spec a Holidaypac Sandwich Box?
Tell the Holidaypac team your size, your filling weight, your fridge or hot-hold temperature, and your target volume. Holidaypac comes back inside two working days with a costed sample, a dieline preview, and a sustainability claim sheet for your retailer audit.
Get a Costed Sample from Holidaypac
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