What Are the Standard Cigarette Box Dimensions in the USA?

If you are a smoke shop owner, wholesaler, or a shipping manager then you definitely know that there is no universal size of a cigarette box. It comes in a variety of shapes, sizes, designs and materials to meet different branding requirements and consumer preferences. But, isn’t it funny how a cigarette pack always feels the same? Well, it’s not a coincidence. It’s just that most brands still follow the 50 years old packaging standards to ensure product safety, uniformity, and seamless supply chain. So, if you are designing custom cigarette packaging boxes or calculating shipping volumes, you need the hard data on US cigarette box dimensions. Therefore, in this blog we have compiled the official measurements of cigarette packs for you. Let’s break them down!

Decoding standard cigarette box dimensions

Before we look into the size of a cigarette box or its dimensions, it is important to know how many cigarettes are in a pack? Well, there are 20 cigarettes in a pack. While it might seem like a simple number, this “20-count” standard is actually the cornerstone of the entire tobacco industry. From a mathematical perspective, this number serves as the benchmark for structural stability. For instance, if you remove 5 cigarettes, the box might crush. A full 20-count pack acts as its own internal support beam. Whereas as legally it defines cigarette taxes that are calculated per pack of 20.
Thus, according to a 20 cigarette pack following are the different cigarette box dimensions and sizes.

King size box

The “King Size” flip-top box is the market leader of the US tobacco industry. While the internal dimensions of the box is 85mm x 55mm x 20mm. The outer dimensions of a king size box is 89mm x 55mm x 23mm. This 1-2 mm gap allows for precise folding. In inches the box measures 3.5″ x 2.17″ x 0.91″. When you open a new king size pack, you’ll see the 20 smokes aren’t lined up in even rows but in a 7-6-7 formation. This arrangement creates a “friction lock. It provides just enough tension to keep the cigarettes from moving vertically or horizontally and keep them intact inside the box.

The long 100 mm cigarette box size

In the tobacco industry a long 100 mm box is referred to as “100s” and are the taller siblings of the standard King Size. While the cigarettes themselves are longer, the dimensions of a cigarette pack is quite similar to the king size box. Take a look:

• In millimeters: 105mm x 55mm x 23mm
• In inches: 4.13″ x 2.17″ x 0.91″

When looking at a king size and a 100s cigarette box dimensions you’ll only find the difference in height. The 100s pack is roughly 16mm (0.6 inches) taller than a king size. Therefore, 100s fit perfectly into the same plastic retail “pushers” and vending machine slots.

Slim cigarette pack

While the king size and 100s focus on height, the “Slim” cigarette box is all about the width and depth. Also, in slim packs instead of 7-6-7 formation there are two rows of 10. Because the cigarettes are so thin that a 10+10 stack results in a box that is much thinner (12–15mm) than a standard pack (23mm). That’s why these boxes require special “spacers” or dedicated narrow tracks in retail display shelves, as they would tip over in a standard king size pusher. Their dimensions are:

• In millimeters: 105mm x 44mm x 12mm
• In inches: 4.13″ x 1.73″ x 0.47″

Dimensions of a 10-pack cigarette carton

Up till now we were looking at the small pocket-size affordable cardboard cigarette boxes. Now let’s explore a bigger picture of cartons. The carton, often referred to as a “200-count box” , is the fundamental unit of measurement for shipping and retail inventory. In the USA, a 200s box is a carton containing 10 individual packs of 20 cigarettes each, totaling 200 cigarettes. Here is the list different carton sizes and their dimensions:

Key considerations for designing custom cigarette boxes

It’s a common misconception that the size or dimensions of a cigarette box are solely a result of the cigarette length. However, the dimensions are actually meticulously engineered based on the following factors:

The standard cigarette count

The number of cigarettes in a box matters because it decides the dimensions of the box. For a standard 20 cigarette box the dimensions are 3.5″ x 2.17″ x 0.91″. But if there are only 10 or 15 cigarettes then the size of the box will be different.

Shape and size of cigarettes

Cigarettes, shape, and size play a critical role in defining the box’s length, width, and depth. Because some of them include slims, unfiltered, cork tips, and filtered.

The “7-6-7” structural geometry

​As we touched on earlier, the internal layout is the biggest driver of the box’s depth and width. To fit 20 cylinders into a compact space, they must be arranged in 10+10 or 7-6-7 formation to provide a stable support that prevents the box from collapsing when squeezed. This is why the arrangement totally changes the box’s dimensions.

Box styles

Cigarette boxes come in various designs and styles such as flip-top lids, soft packs, and rounded corners. The style you choose greatly affects the packaging size.
​So if you are designing custom printed packaging boxes, remember these are the four critical factors that dictate the cigarette box dimensions.

5 simple steps of packing a box of cigarettes

In the tobacco industry, “packing” isn’t just about putting a product in a box. It is a high-stakes engineering requirement. Because if there is even a minute millimeter of difference in packaging, your cigarette might become unusable. Therefore, it is important to know how to pack a box of cigarettes.

• Start by laying out the 20 sticks in a 7-6-7 formation inside the 23 mm deep box.
• Before the cigarettes go into the cardboard, wrap them in a piece of paper-backed foil or moisture-proof film.
• Pack the cigarettes snugly at the bottom of the foil.
• Next insert foil bundle (from top or bottom) into the box sleeve.
• In the end tuck the lower flaps and seal them with a glue and cover the box with a transparent BOPP layer.

Conclusion

As we have explored cigarette box dimensions, just remember 85mm x 55mm x 23mm is the standard of a king pack and the extended 105mm height of a 100s box. These measurements ensure that every box fits perfectly into retail pushers, shipping cartons, and the consumer’s pocket. If you want these précised-cut cardboard cigarette boxes you can get from Boxit Packages. We have been working with tobacco companies for over a decade and manufacture high-quality boxes. Contact us for more details.

Frequently Asked Questions

What are the dimensions of a 10-cigarette pack?

A pack of 10- cigarettes falls in a slim packaging category. The dimensions of this box are 3.5" x 1.6" x 0.7".

What are the dimensions of a 5-cigarette pack?

A pack of 5-cigarettes is similar to the 10-cigarette pack, it only varies in depth. Thus, the box dimensions are 3.5"' x 1.6" x 0.45"

How long is a cigarette?

Cigarettes typically measure 84 mm (king size), 100 mm (long size), and 120 mm (extra-long size).

What materials are used for cigarette boxes?

The best and eco-friendly option for manufacturing cigarette boxes is cardboard, Kraft, and rigid board (for premium boxes)

How does the USA cigarette pack size compare to other countries?

USA cigarette boxes are similar to the boxes in the UK however, they differ from Canadian standards which is 85mm x 55mm x 20mm.