Chocolate Bar Packaging: Wrappers, Envelopes and Bar Boxes

What does this range cover?

Three products for bars of every size. Chocolate Bar Wrappers and Sleeves are the printed outer layer that folds or slides around a foiled bar. Chocolate Envelopes fold around thin bars and chocolate cards like a letter. Chocolate Bar Boxes are slim card boxes in tuck end and wallet styles.

In each case the bar keeps its own inner wrap, usually foil or a sealed inner, and our printed packaging goes over the top. That is where your brand, the flavour and the details live.

The range suits bean to bar makers, cafes that make their own bars, gift shops with a local range and companies ordering branded bars for events. A first order is often a single bar size in three or four flavours.

Wrapper, envelope or box: which is right?

A wrapper keeps cost and thickness low. A box protects corners and stands up. An envelope is the most personal. Many makers use a wrapper for their core bars and a box or envelope for gifts.

For the full comparison, see our guide to wrappers versus bar boxes.

How do you measure a bar for packaging?

Thickness is the measurement most often missed. A bar topped with nuts or fruit can be twice as thick as a plain one from the same mould.

1. Wrap one bar in its foil or inner, exactly as you sell it.
2. Measure the length and width in mm.
3. Measure the thickness at the thickest point, including inclusions.
4. Note whether the bar will be sold flat or standing up.
5. Send the three numbers with the product you have in mind.

What should a bar pack say?

Bars carry more information than boxes of chocolates, because they are often sold through other shops. Plan room for each of these on the back or sides.

• Bar name, cocoa percentage and flavour
• Ingredients and allergen information
• Weight and your business address
• A barcode area, if you sell through other retailers
• A short line about the beans or the maker

Which finishes suit bar packaging?

Matt paper suits craft and single-origin bars and takes a hand-stamped batch number well. Gloss makes bright colours livelier. Soft touch on a sleeve or box gives a smooth feel for gift bars, and foil on the logo looks crisp on firm card.

All print in the range uses food-safe inks, on paper or card.

Can several flavours share one order?

Yes, and it is the usual way bar packaging is ordered. Each flavour gets its own design on the same size, so the cutting and folding stay the same while the colours change. On a shelf, a row of bars in different colours but one layout reads clearly as one brand.

If you only want one design, a plain wrapper with a printed flavour sticker is another option for small runs.

Who orders bar packaging, and how much?

Small makers often begin with a few hundred wrappers per flavour, printed in one run, and move to boxes once a stockist asks for something that stands on a shelf. Gift shops and hotels tend to order envelopes or wallet boxes for one occasion at a time, with a logo and a short message.

Because minimums are low and quoted per job, you can start with the format that suits your sales today and add another later without changing your bar size. The same measurements carry across wrappers, sleeves, envelopes and boxes, so a design can move from one to another with only small changes to the layout.

How long does bar packaging take?

Production is 4 to 6 working days from proof approval for every product in this range. Parcels then take 2 to 3 working days to reach you, tracked and free anywhere on the UK mainland. Wrappers arrive as flat printed sheets; sleeves, envelopes and boxes arrive flat and ready to fold.

Prices start from £0.25 a box for card styles and come back on your quote by email within one working day. Minimums are low and set per job.