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Barton Jones Packaging Ltd
Industry solutions

Balloon boxes and balloon-in-a-box packaging

Made-to-measure corrugated balloon boxes for bubble balloons, balloon-in-a-box gifts and event hampers, manufactured in Letchworth and courier-ready across the UK.

The problem

What usually goes wrong

Balloon-in-a-box gifts fail when the box is too small, the wrong shape, or not strong enough to hold an inflated bubble balloon without bowing.

Off-the-shelf boxes rarely match an inflated balloon's diameter, so the balloon either squashes against the walls and pops, or rattles around and loses its presentation.

Event and hamper packs also need to survive a courier journey upright, which a stock box is not designed for.

Typical pack

Packaging components we usually specify

  • Tall 0201 cube boxes sized around the inflated balloon diameter
  • Shallow hamper trays for balloon-and-gift hampers
  • Window lantern boxes with carry handles for presentation gifts
  • Printed litho-laminated or digitally printed gift outers
  • Internal fitments and partitions to hold accessories in place
  • Fragile and this-way-up handling marks printed on the outer

Materials

Relevant materials and board grades

  • Single wall for lightweight balloon-only gift boxes
  • BC double wall for tall cubes holding large bubble balloons
  • White or kraft liners depending on presentation needs
  • FSC certified board under licence C214479 for chain-of-custody claims

In-house

Our manufacturing and assembly capabilities

  • Made-to-measure boxes cut on our own box-making machines in Letchworth, so the box fits the inflated balloon
  • No minimum on stock lines and bespoke runs from as little as one
  • Prototype and sample before commitment, so you can test the fit with a real balloon
  • Printed outers carrying your branding and event messaging
  • Assembly and kitting where a pack needs accessories or inserts fitted

Stock holding

How we hold stock for you

  • Hold your standard balloon box sizes and call them off against event schedules
  • Buy at volume pricing, take delivery only as you need the space
  • Scheduled deliveries on our own vehicles, free on orders over £100 within 30 miles of Letchworth

Accreditations

Relevant accreditations for this sector

  • FSC C214479
  • BRCGS Storage & Distribution
  • Verified Carbon Standard
See our accreditations and request the literature

Real example

Right-sized cubes that stopped balloon pop-ons

A balloon gifting business was buying stock cubes that were either too tight, causing balloons to pop against the walls, or too large, so the presentation fell flat on opening.

We measured their most common inflated bubble balloon diameter and made a tall 0201 cube to fit it with a small clearance, in BC double wall so the panels stay flat under the courier's stacking.

Pop-on rate dropped to near zero, the box presents the balloon properly on opening, and the cube now matches a standard courier size band.

Go deeper

More on balloon packaging

Sector enquiry

Tell us your inflated balloon diameter

Send the diameter of the balloon you inflate most often and how many boxes go out a month. We will size a cube to fit and send a sample to test.

  • Inflated balloon diameter (mm)
  • Balloon type: bubble, foil, or latex cluster
  • Single balloon or balloon-plus-gift hamper
  • Courier or own delivery, and monthly volume
Use the enquiry form01462 680888

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