A Detailed Guide to Make Tuck End Packaging for Tobacco Products

Tuck end packaging is an important consideration for tobacco products because it provides a seal to keep the product fresh, prevents tampering and theft, enhances brand recognition by making your product stand out on store shelves, and protects consumers from accidental exposure. This blog post will discuss tuck ends in detail so that you can choose the best option for your company’s tobacco products.

The benefits of each type are reviewed as well as how to create them. Finally, some additional considerations are discussed, such as what materials work best for custom pre roll boxes and where you should have your tucks ends placed. Here, we will talk about each type separately in this article. Let’s start!

Step 1: Prepare Cigar Boxes for Tuck End Packaging

To make tuck end boxes for your cigars, it is good to prepare. First, you need to take off the original band of your cigar box with a hot air gun or hairdryer at less than 100C which is usually the temperature of a hot air gun. Then, you need to cut a piece of paperboard that’s just a bit larger than a cigar box cover. After that, carefully tear off some excess paper from the top and bottom edge of the box. Make it a little smaller than cardstock or paperboard size. Keep all these little things for later use.

Step 2: Cut Paperboard Slightly Larger Than Cigar Box Cover

For this step, we recommend using a Rotary Cutter instead of a Utility Knife. With the Rotary Cutter, you can cut with confidence since it has a guide on the blade and won’t slip when you use it to cut up the box cover. The rotary cutter has a blade with a circular wheel on one end, which makes the process faster and safer. To cut a straight line with a rotary cutter, put a cutting mat on top of the blade so you always know where to cut.

Step 3: Punching Holes on Cigar Box Cover

Use a Brad Nail or a Staple Gun to punch holes in the top and bottom edges of your cigar box cover. Put them in places where there is a matching paperboard. To make a hole in the cardstock, use a hole puncher. If you use a hammer, it will take more time. A hole puncher can make holes of any size. Make sure the holes are evenly spaced from each other, and make sure a 4mm nail or staple can fit in them.

Step 4: Paper Tuck End Packaging Wrapping and Closing the Box

After we put holes in the cigar box, we put a paperboard on top. We had to line it up and glue it. Let’s use tape or staples instead of glue because if you use too much glue, the box will be see-through.

Once you are done making the cigar, you should close it up by tucking in the ends of paper wraps around them, then folding them down and pasting them to themselves. Holding and keeping the end closed for about 20 seconds will make the bag stay closed.

There are several kinds of boxes available at https://stampaprints.com/pre-roll-packaging/, so you can contact them to get the best quality tuck top packages for your business.

Step 5: Use of Adhesives to Make the Box

Once the box is finished, you need to attach the hinges and latch so it can be closed without any problems. Attach a small metal hinge on one side of the box. Then attach a small latch on the other side of the box. While your cigar pack can still open up after that, you should make sure everything is neat and properly attached for the finished product effect.

To do this, you need to place adhesive between the hinges and the gaps in the latches. Then you glue them down firmly with adhesive. Put some glue under the hinges and under the latch. It will stay closed because it is glued together.

Step 6: Printing of the Box

Now that the packaging box is fully assembled, the design can be placed on the cigar box. To make your custom cigar box more attractive to people, use a piece of an old magazine or some scrapbook materials. Cut out the desired images and paste them on the trunk of your custom cigar box using adhesive.

If you want to make this kind of tobacco product storage even more useful, fit your customized lighter holder inside carefully. If you are having difficulty finding pre-made lighters holders for cigars, try making one yourself by rolling up small pieces of paper or thin cardboard then tying them together with yarn or string tightly at both ends.

This printing plays a vigorous role in the business promotion. A simple and dull looking packaging box will make no impact on the customers. So, it will do noting for your product’s marketing campaign. In contrast, if you are using striking packaging boxes it will entice your customers. So, if you want to make your product stand out among the rest, never forget the importance of quality printing for your goods packaging.

Step 7: Finishing Touches

You should let all of your adhesive dry before you proceed to the next step. If the tuck end boxes are already dry and set, skip this part. Then apply a thin layer of varnish onto the whole box so it will look more polished. You can also add closures such as string ties or metal wire twist-ties. Decorate your cigar box with ribbons, trim pieces, beads, buttons, rosettes, and large paper flowers for an extra special touch!


Creating your own cigar box is very multi-faceted. It requires patience, meticulousness, and craftsmanship to get the job done right. But when you finish a project, it won’t be so bad. And you can smoke the cigars or cigarettes that you made.

I hope you have found enough information about the concept of cigar box building; thanks to the elementary article I wrote. Please do not hesitate to comment if you have any questions! I will get back to you as soon as possible.

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