Why Happy Meal Boxes are Essential for Kids' Meals?
iCustomBoxes offer you custom happy meal boxes that will prove to be the ultimate marketing strategy for you. These boxes can be designed with eye-catching and vibrant graphics to catch kids’ attention. Moreover, our food-safe material can keep the food fresh.
We can design these boxes with add-ons and finishes. The usefulness and aesthetics of these boxes will convince the parents to buy them for their kids.
Moreover, we use eco-friendly and FSC-certified packaging materials. This is another factor that will increase your brand loyalty.
Our kids' meal designed boxes are perfect for fast-food chains and cafés, they help attract families and strengthen your restaurant branding.
With over 15 years of experience in food packaging, we consistently deliver boxes that meet industry standards and maintain top-tier quality.
Material Options for Kids Meal Boxes in the U.S. Market
Choosing the right material is the foundation of creating durable, safe, and visually appealing Happy Meal boxes. In the U.S., manufacturers select materials based on food safety compliance, print quality, structural strength, and sustainability.
Solid Bleached Sulfate (SBS) Board:
We use SBS when brands require premium print quality and superior structural integrity. SBS provides a bright white surface that makes colors and characters pop in high definition. Its smooth coating ensures sharp details for logos, promotional art, and character designs.
SBS is FDA-compliant, which makes it safe for direct contact with food items, including sandwiches, fries, or small desserts. Its rigidity prevents sagging or bending during transportation, assembly, or handling by children.
Folding Box Board (FBB):
FBB offers a cost-effective alternative without compromising quality. It features multiple layers, including recycled fibers, which add strength while keeping the material lightweight.
We use FBB for inserts, secondary compartments, or boxes that do not need the full vibrancy of SBS printing. Its smooth surface handles high-quality graphics well, and the multi-ply structure ensures boxes remain durable even when filled with meals and toys.
Kraft Paperboard:
Brands increasingly choose Kraft paperboard for sustainable, eco-friendly packaging. Its natural brown color gives an organic and earthy feel. While it does not provide the same brightness as SBS, we enhance designs using white or light inks, which create clear, visible graphics and branding.
Kraft is strong, holds its shape under normal handling, and is 100% recyclable, making it ideal for eco-conscious campaigns.
Coated Recycled Board (CRB):
CRB combines recycled fibers with a coating to improve print quality and structural stability. We use CRB primarily for secondary packaging, such as inserts, dividers, or promotional add-ons. Its coated surface allows detailed printing, and it supports brands that prioritize environmental responsibility and cost efficiency.
We carefully choose materials that balance strength, safety, sustainability, and aesthetic appeal, ensuring that every box delivers a consistent, high-quality experience for both children and restaurants.
Choose the Right Size and Inserts for Happy Meal Box
Choosing the right size for your packaging is significantly important. An accurate happy meal box size fits the product in the right manner and avoids any spillage or squishing.
Happy meals mostly consist of burgers, fries, a toy, and juice. All of these food items require proper packaging.
Let’s explore some common kids' meal packaging sizes together. Keep in mind that these custom box sizes are standard. At iCustomBoxes, we can create a box by following your food packaging requirements.
Small HappyMeal Boxes:
5.5 x 3.5 x 4.5 “ Inches
Medium HappyMeal Boxes:
6.5 x 4 x 5” Inches
Large HappyMeal Boxes:
7.5 x 4.5 x 6” Inches
We can create your boxes with separate compartments for all product needs. These custom inserts offer steady protection to your food. We add greaseproof liners and inserts to ensure spill-proof food packaging.
Popular Box Designs and Structures
We design McDonalds Happy Meal boxes to accommodate meals, toys, and promotional elements while ensuring they remain functional and child-friendly.
Classic Gable-Top Box:
The gable-top design includes a built-in handle for easy carrying. Its side and end panels lock securely, and the bottom supports heavier meals. This structure is ideal for restaurants that need easy-to-assemble gable boxes that perform reliably.
Auto-Lock Bottom Box:
We incorporate auto-lock bottoms for boxes that require fast assembly and extra strength. This design keeps the box securely closed, even when filled with food and toys.
Boxes with Inserts:
Inserts create compartments within the box, separating toys from food. We design inserts to be sturdy, lightweight, and easy to remove, ensuring meals remain organized and hygienic.
Character-Shaped or Punch-Out Boxes:
We cut boxes into themed shapes to match promotional campaigns. The gable top can be modified to include ears, faces, or other interactive elements. Despite their playful design, we maintain structural strength and usability.
Selecting the right structure ensures ease of use, durability, and an engaging experience for children.
Printing Options and Color Management
We approach printing with a focus on brand consistency, vibrant visuals, and food safety.
CMYK 4-Color Process:
CMYK provides full-color printing for photos, characters, and gradients. We use it to create eye-catching designs that appeal to children.
Pantone Spot Colors:
When a brand requires exact color matching, we employ Pantone spot colors. This guarantees color consistency across all boxes.
White Ink Printing:
White ink stands out on Kraft or colored boards, allowing logos and artwork to remain visible and vibrant.
Interior Printing:
We can print games, puzzles, or messages inside the box. This adds an interactive element for children without compromising safety or structural integrity.
Printing choices directly impact the visual appeal and brand identity of the packaging.
Add-Ons for Your Happy Meal Packaging
Give your custom packaging a premium, branded finish with our exclusive add-on options. These finishing touches not only enhance the look and feel of your boxes but also make your packaging stand out in the food industry.
Whether you want a glossy shine or a subtle matte texture, our finishing techniques ensure a luxurious and professional appearance for every box.
Spot UV:
Highlight your logo or artwork with a glossy shine for a striking contrast.
Gloss Lamination:
Adds a sleek, polished surface that enhances color vibrancy.
Matte Lamination:
Gives your packaging a smooth, elegant finish with a refined touch.
Embossing:
Raises specific design elements for a premium, textured look.
Debossing:
Creates an indented effect for a subtle, sophisticated impression.
Foiling (Gold & Silver):
Add metallic accents that exude luxury and catch instant attention.
These finishing, foil stamping, embossing, and spot UV, are some beautiful finishes that will make your custom packaging turn into branded meal boxes.
Adhesives and Gluing Techniques
We rely on FDA-compliant adhesives to ensure boxes hold up under real-world use:
Cold-Glue (PVA):
Provides strong adhesion while remaining safe for direct or indirect food contact.
Hot-Melt Adhesive:
Speeds up production while maintaining box durability.
Choosing the right adhesive ensures boxes remain securely closed during transport and handling.
Benefits of Custom Happy Meal Boxes!
Our personalized happy meal boxes creates a fun and exciting experience for your customers. These boxes also offer a clean and mess-free design to parents who are worried about their kids spilling food. Our packaging will help you increase your brand recognition.
Our packaging falls under the safety and hygiene standards. We follow the government-issued regulatory compliance just to offer you food-safe packaging.
The eco-friendly material will represent you as an environmentally conscious brand. This way, you can enhance your customers’ experience and build brand loyalty.
Buy Happy Meal Boxes Wholesale at Affordable Prices in USA
Order Happy Meal boxes packaging at wholesale and get big discounts. We ensure cost-effectiveness for all types of bulk orders. For your food packaging, we offer you low rates.
Whether you are a retail supplier, a food chain, a takeaway business, or a caterer, we offer our wholesale deals to all. Place your order for bulk food Packaging right away, only at iCustomBoxes.
We help brands design and produce packaging custom Happy Meal boxes that meet U.S. food safety regulations, provide vivid graphics, and use durable, sustainable materials. Send us your product specifications and get a free quote right away.
