Custom Burger Boxes

Burger Box Styles We Offer

We manufacture custom burger boxes across a range of styles to suit different burger formats and service contexts. All styles are available in custom sizes, materials, and finishes.

Standard Burger Boxes

The format for everyday fast food burgers – a square or rectangular box with adequate height for a standard burger, a secure closure, and a grease-resistant interior. Available in a range of sizes to suit different burger diameters, from small single-patty formats through to large double-patty burgers.

The standard burger box is assembled quickly during peak service, holds the burger reliably during transport, and provides a clean brand surface on the exterior. For fast food operators serving high volumes, the assembly speed and closure reliability of the format are practical requirements alongside the design.

Gourmet Burger Boxes

A format for premium and artisan burgers – tall, generously filled, with quality ingredients and a presentation that warrants a better box. Gourmet burger boxes need to accommodate significant height variation, communicate the premium positioning of the product, and open to a first impression that matches what the customer paid for.

Available with taller lid configurations to accommodate stacked burgers, with premium board weights and print treatments, and with interior configurations that hold the burger in position without it collapsing before the customer gets to it. For gourmet burger restaurants, the box is as much a part of the product as the bun.

Slider Boxes

A format for sliders and mini burgers – smaller versions of the standard burger format, typically served in multiples of two, three, or four. Slider boxes are used by gourmet burger restaurants offering tasting menus, by event caterers serving cocktail food, and by restaurants with slider-format menu items.

Available in individual and multi-slider configurations. For multi-slider formats, the interior configuration needs to hold each slider in position without them touching each other – slider-to-slider contact during transport causes the buns to compress and the fillings to be displaced.

Burger Meal Boxes

A format for complete meal configurations – burger, chips, a side, and a sauce in a single box or coordinated packaging set. Meal boxes are used by fast food restaurants for value meal offerings and increasingly by delivery platforms where the complete meal is the primary order format.

The configuration challenge is holding the hot burger and chips alongside any cold components without the temperature difference affecting the quality of either. For meal boxes that include a separate sauce or condiment, the sauce container needs to be held securely in a position where it won’t tip and leak onto the burger during transport.

Double and Stacked Burger Boxes

A format specifically for tall burgers – double patty, triple patty, or heavily loaded burgers that exceed the height of a standard burger box. These boxes need a significantly taller lid configuration, a more robust base to support the additional weight, and a design that accommodates and showcases the impressive height of the product.

For gourmet burger restaurants where the tall, stacked burger is a signature product, the box height is not just a structural requirement – it’s a communication of the product’s character. A box that’s proportionally matched to a very tall burger communicates the generosity of the product before it’s even opened.

Choosing the Right Burger Box Configuration

The configuration decisions for burger boxes depend on the burger height, the filling profile, and the service context.

Burger height is the most variable and most important dimension. A standard fast food burger – single patty, standard toppings, flat bun – might be 6 to 8 centimetres tall. A gourmet burger with two thick patties, melted cheese, a generous sauce application, lettuce, tomato, pickles, and a brioche bun might be 13 to 15 centimetres tall. The interior height of the box needs to accommodate the burger without the lid pressing down on the top bun. A lid that compresses the top bun distorts the burger’s structure, pushes the fillings outward, and produces a product that looks significantly less impressive than it did when it was assembled. Measure the actual height of your burger as served – not the estimated height – before specifying the box.

Clamshell vs two-piece construction. A clamshell box – where the lid and base are connected by a fold and open together – is faster to assemble than a two-piece box where the lid is separate from the base. For high-volume service, the clamshell format saves time across hundreds of units. A two-piece format gives more flexibility in lid height relative to base height, which can be useful for very tall burgers where the standard clamshell proportions don’t work. The right choice depends on the burger height and the service volume.

Interior width and diameter. Burger diameters vary – a 100-gram single patty burger is substantially narrower than a 200-gram double smash patty burger. The interior of the box needs to accommodate the burger’s diameter with a small clearance on each side to prevent the bun from being compressed against the box walls. A box that’s too narrow squeezes the bun; a box that’s too wide allows the burger to move and tip during transport.

Sauce containment for heavily sauced burgers. A smash burger or a loaded burger with multiple sauce applications – aioli, special sauce, mustard, ketchup – produces a significant amount of liquid that pools at the base of the box. The base needs to be grease-resistant and liquid-resistant to manage this. For premium burgers where the sauce is a key flavour element, the sauce pooling at the base is also a visual and eating quality consideration – a sauce that’s migrated to the base of the box isn’t on the burger where it was intended to be.

Burger Box-Specific Considerations

A few properties of burgers that create specific packaging requirements.

Opening the box is a moment of product reveal. When a customer opens a burger box, the first thing they see is the top bun – and for a well-made burger, that’s intentional. The top bun is the most visually finished surface of the product – it might be sesame-studded, glazed with butter, or branded with the restaurant’s mark. The interior of the lid should not make contact with the top bun – any contact marks the bun surface and diminishes the reveal. The lid interior should be smooth, food-safe, and high enough to clear the bun without touching it.

Gourmet burger culture has fundamentally changed packaging expectations. The growth of the gourmet burger market in Australia over the past decade has created a consumer group that pays $18 to $25 for a burger and expects the packaging to reflect that price point. A well-made gourmet burger in a low-quality generic box is a disconnect that this consumer notices immediately. The packaging is part of what the customer is paying for – a considered box that opens to a beautifully presented product, and that communicates the brand’s identity and values, is a component of the premium experience.

Toasted bun crispness is vulnerable in a sealed box. A brioche or milk bun that’s been toasted has a slightly crispy exterior surface that softens in the steam environment of a sealed box within minutes of packaging. For burgers eaten immediately at the counter, this is less critical. For delivery burgers where the product may spend fifteen to twenty minutes in a box before consumption, the bun texture on arrival is noticeably different to what it was at the point of service. Ventilation in the box lid can slow this softening, though the tradeoff with heat retention needs to be considered.

The interior of the box contributes to the brand experience. For premium burger brands, the interior of the box – the base, the lid interior, and any interior print – is part of the packaging experience. A burger box that’s plain on the exterior and inside is a missed opportunity; a burger box with branded interior print, a signature colour on the interior, or a message to the customer creates an additional brand touchpoint that’s seen at the moment of maximum product anticipation. For gourmet burger restaurants that care about every detail of the experience, the interior of the box is worth designing.

Food truck burger packaging needs to work in a constrained environment. A food truck kitchen has significantly less bench space than a fixed restaurant kitchen. Packaging that requires a large assembly area, multiple pieces to manage simultaneously, or careful positioning to close correctly is a liability in a food truck service context. For food truck operators, a format that can be assembled, filled, and closed with one hand while the other is occupied with the burger itself is a practical requirement.

Print & Finishing for Burger Boxes

Burger packaging has the most varied visual landscape of any fast food category – the range from national chain design to artisan food truck identity is wider than in almost any other format.

National chain burger packaging needs to deliver visual consistency and brand recognition across every location in the network. The design system is established; the packaging executes it consistently. For national chains, the most important packaging attributes are print consistency, material consistency, and reliable supply at volume. Full colour CMYK on white or coloured board is the standard approach.

Gourmet burger restaurant packaging is where the most interesting design work in the category happens. Gourmet burger restaurants in Australia have developed some of the strongest and most distinctive brand identities in the fast food category – bold illustration, irreverent typography, strong colour, and design that expresses the personality of the restaurant as clearly as the menu does. For these operators, the burger box is a canvas that rewards creative investment. A well-designed burger box from a well-regarded gourmet burger restaurant is a brand asset that travels beyond the restaurant and into the customer’s daily life.

Food truck burger packaging benefits from the same creative freedom as gourmet restaurant packaging, often with a more casual, handmade quality to the design that communicates the informality and personality of the food truck context. Bold, screen-print-inspired graphics, limited colour palettes, and design that references the street food culture of the food truck scene all work well in this context.

Interior print for premium burger boxes adds a brand touchpoint that’s visible at the moment of maximum product anticipation – the opening of the box. A simple brand mark, a brand colour, or a message to the customer on the interior lid creates an additional brand moment that plain packaging doesn’t have.

All boxes are printed using full colour printing in CMYK. Files should be supplied as Adobe Illustrator (.ai) or high-resolution print-ready PDF, with fonts outlined and graphics embedded. Free design support is included – we’ll produce a free 3D mockup for your approval before production begins, and handle minor artwork adjustments at no extra charge. Free dieline templates are available if you’re building your artwork from scratch.

Materials & Specifications

We manufacture burger boxes in a full range of cardboard and paperboard materials, with grease-resistant and liquid-resistant options for heavily sauced burger applications. Eco friendly and recyclable options are available across the range. All materials are food grade and food safe.

• Single copper paper
• White kraft
• Brown kraft
• Black kraft
• Gold foil paper
• Silver foil paper
• Corrugated board

Minimum order quantity is 1,000 units. Air freight runs approximately 3 – 4 weeks from production sign-off; sea freight is approximately 8 weeks. We supply burger restaurants and food trucks across Australia including Sydney, Melbourne, and Brisbane. For more detail on the full order process, artwork requirements, and lead times, get in touch and we’ll walk you through it.