Quick Answer
The cannabis packaging industry has achieved a breakthrough: the world's first 100% paperboard, child-resistant cigarette-style box for pre-rolls. Developed by Contempo Specialty Packaging and certified under 16 CFR Part 1700, this plastic-free innovation eliminates the traditional flip-top design's vulnerability to tearing — a weakness that previously made cigarette-style boxes fail child-resistance testing. Available in FSC-certified or recycled paperboard with customizable sizing and premium finishes, this solution marks a significant step toward balancing safety with sustainability in cannabis packaging.
The Breakthrough: Paperboard Meets Child-Resistance
Creating paperboard cannabis packaging that passes child-resistant testing has historically been challenging, but designing a child-resistant cigarette pack presented the greatest hurdle . Traditional cigarette boxes feature flip-top designs that are vulnerable to tearing during child-resistant testing, making them accessible to children .
Contempo Specialty Packaging has solved this problem with a durable, secure, and completely plastic-free structure that successfully passes rigorous child-resistant testing protocols . This innovation delivers both the safety requirements and sustainability demands of today's cannabis market .
The box is certified as child-resistant according to 16 CFR Part 1700, making it the first plastic-free cigarette box to achieve this certification . Available in FSC-certified board or recycled paperboard versions, the box is "easily recyclable" at end-of-life .
Why This Innovation Matters
The Challenge of Traditional Packaging
The cannabis industry has long grappled with a fundamental tension: child-resistant packaging requires certain mechanical complexity, while sustainable packaging aims to minimize materials and avoid plastics. Historically, these two goals have been difficult to reconcile.
Most child-resistant cannabis packaging relies on plastic components:
-
Plastic CR zippers on mylar bags
-
Plastic press-and-turn closures on jars
-
Plastic pop-top mechanisms on pre-roll tubes
These plastic components make packaging difficult to recycle and contribute to the industry's heavy reliance on single-use plastics . As regulations tighten and consumer demand for sustainability grows, the need for plastic-free CR solutions has become urgent.
The Traditional Cigarette Box Problem
Pre-rolls are one of the fastest-growing segments in the cannabis market. A 2023 report from Headset found that pre-rolls made up 15.3% of total cannabis sales in the U.S. and 33.3% of total sales in Canada . Recent data projects that the pre-roll market will generate $5 billion in revenue by 2030 .
The cigarette-style box format is familiar and appealing to consumers . However, the traditional flip-top design has a critical weakness: during child-resistance testing, children can simply tear the box open to access the contents . This made it impossible to certify conventional cigarette boxes as child-resistant.
The Solution
Contempo's design addresses this issue by offering a durable, secure structure that passes rigorous child-resistant testing while maintaining the familiar cigarette-style opening experience consumers love .
"Since Contempo began serving the cannabis industry in 2017, we've received countless customer requests for a truly sustainable child-resistant box that opens like a traditional cigarette box," said Contempo Specialty Packaging CEO Michael Markarian .
"Utilizing plastic parts for the hinge would have been the easy answer, but that runs counter to our mission of sustainability. With our 100% paperboard child-resistant cigarette box, we're elated to fill a niche in the cannabis packaging market and bring producers another innovative, beautiful, sustainable, and child-resistant packaging option that measures up to the care and quality they bring to their cannabis."
Key Features of the Paperboard CR Box
100% Paperboard Construction
The box is made entirely from paperboard, eliminating plastic from the packaging structure entirely. This represents a significant departure from traditional child-resistant packaging, which often relies on plastic inserts, blister packs, or complex mechanisms that are difficult to recycle .
Material Options:
-
FSC-certified board — ensures sustainable forestry practices
-
Recycled paperboard — supports circular economy principles
Both options are "easily recyclable" at end-of-life, addressing the growing consumer demand for packaging that doesn't end up in landfill .
Child-Resistant Certification
The box is certified according to 16 CFR Part 1700, the federal standard for child-resistant packaging . This certification demonstrates that the packaging has passed rigorous testing with children aged 42–51 months, meeting the requirement that at least 80% of children cannot open the package within 5 minutes.
Customizable Sizing
The box size can be fully customized to accommodate different quantities or sizes of pre-rolls, ensuring a perfect fit for any product . This flexibility makes it suitable for:
-
Single pre-rolls
-
Multi-packs (2, 3, 5, or more)
-
Different pre-roll lengths (78mm, 90mm, 98mm, 109mm, 116mm, 120mm)
Premium Finishes
The box is compatible with various print finishes and embellishments, allowing brands to maintain a premium look while using sustainable materials :
-
Hot stamping — metallic foil accents
-
Spot UV — glossy highlights
-
Soy-based inks — eco-friendly printing
The Broader Trend: Paperboard Innovation in Cannabis
Contempo's breakthrough isn't an isolated innovation. Several companies are pushing the boundaries of paperboard child-resistant packaging:
Burgopak & Global Packaging
Burgopak, in collaboration with Global Packaging, has unveiled a child-resistant cannabis box made entirely from paperboard that meets ISO 8317 standards . This solution uses an internal sliding tray mechanism with a child-resistant locking feature .
The consumer must perform a two-step action—pressing tabs while sliding the tray—to access the contents . This system complies with ISO 8317 standards, making it a viable solution for regulated cannabis markets in North America and beyond .
Key Benefits:
-
All-paperboard structure — 100% recyclable in most curbside programs
-
FSC-certified materials
-
Designed for high-speed automated filling lines
-
Premium feel with smooth opening motion
Earthycores
Earthycores manufactures child-resistant paper tubes certified to 16 CFR 1700.20 standards, featuring airtight sealing and foil inner lining for product protection . All materials are FSC-certified, 100% recyclable, and printed with plant-based soy inks .
Key Features:
-
100% paper-based — no plastic push-ups, films, or hidden plastics
-
Independently tested and certified
-
Airtight sealing with foil inner lining
-
Custom sizes from 1,000 units
-
Production capacity of 500,000 tubes per month
Hoffmann Neopac
Hoffmann Neopac revealed a fully metal version of its high-barrier, child-resistant tins for dry and semi-dry cannabis products, intended to boost the pack's recyclability and improve its protective qualities .
Keystone Folding Box Co.
Keystone produced a child-resistant blister wallet for hard tablets featuring push-through opening. The pack consumes 75% less plastic than plastic bottles while containing the same amount of product .
Why This Matters for the Cannabis Industry
Pre-Rolls Market Growth
The pre-roll market is expanding rapidly. A 2023 report from Headset found that pre-rolls made up 15.3% of total cannabis sales in the U.S. and 33.3% of total sales in Canada . The pre-roll market is projected to generate $5 billion in revenue by 2030 .
This growth creates significant demand for pre-roll packaging that balances compliance, sustainability, and brand appeal.
Consumer Demand for Sustainability
Studies show that over 92% of consumers say sustainability is important when choosing a brand, and products with environmental, social, and governance (ESG) claims have contributed to 56% of total market growth across multiple categories . The cannabis industry is no exception — consumers increasingly seek out brands that minimize waste and demonstrate environmental responsibility .
Regulatory Pressure
States like New York and Washington are already mandating minimum recycled content in cannabis packaging. New York requires minimum 25% post-consumer recycled content in plastic cannabis packaging. Washington requires 25% PCR through 2030 and 50% from 2031 onward.
Paperboard packaging that is 100% recyclable and uses FSC-certified or recycled materials directly addresses these regulatory requirements.
Reducing Single-Use Plastics
The cannabis industry has been criticized for its heavy reliance on single-use plastics — mylar bags, pop-top tubes, and plastic pre-roll containers . Many cannabis companies are making efforts to invest in sustainable packaging, responding to customer demand and regulatory pressure .
Design Considerations for Paperboard Packaging
Understanding the Full Lifecycle
For a packaging solution to be truly sustainable, it needs to perform at every stage of its journey, from production to disposal . Sustainability is about the full lifecycle, not just the material itself.
The Importance of Component Compatibility
The credibility of sustainable packaging depends on keeping all components — the box, the liner, the closure, and the label — within a single recycling stream . Many sustainable packs fail on one tiny component, such as a foam liner in the cap or a metallic label, that prevents the entire package from being recyclable .
Mono-Material Over Multi-Material
The most credible sustainability approach in 2026 is mono-material packaging — using a single material type throughout the entire package . For paperboard boxes, this means ensuring the closure, liner, and any labeling are compatible with paper recycling streams .
Testing in Real-World Conditions
Packaging that passes laboratory testing may still fail in real-world conditions. Retail testing is essential — put the pack in a busy shop and see if it performs as expected . Many sustainable packs fail this test because the mechanism is confusing or the labeling tears .
How PackTHC Can Help
At PackTHC, we stay current with the latest innovations in cannabis packaging. While we offer a comprehensive range of packaging solutions, we also help brands navigate emerging trends and make informed decisions.
Our Commitment:
-
Compliant Solutions — All packaging meets PPPA and ASTM child-resistance standards
-
Sustainable Options — We offer packaging solutions that balance sustainability with performance
-
Expert Guidance — Our team can help you evaluate emerging packaging technologies
-
Quality You Can Trust — From mylar bags to glass jars, we provide packaging that protects your product and brand
Final Takeaway
The development of 100% paperboard child-resistant packaging represents a significant step forward for the cannabis industry. For the first time, pre-roll brands can offer packaging that:
-
Meets child-resistant compliance — certified under 16 CFR Part 1700
-
Eliminates plastic — 100% paperboard construction
-
Supports sustainability — FSC-certified or recycled materials, fully recyclable
-
Provides premium presentation — customizable with high-end finishes
-
Delivers consumer familiarity — opens like a traditional cigarette box
Key Takeaways:
-
The first plastic-free, child-resistant cigarette box for cannabis pre-rolls is now available
-
Traditional flip-top cigarette boxes failed child-resistance testing due to tear vulnerability
-
Paperboard solutions can be certified under 16 CFR Part 1700 and ISO 8317
-
Multiple companies are innovating in paperboard child-resistant packaging
-
Consumer demand and regulatory pressure are driving the shift to sustainable packaging
FAQ
What is the first plastic-free child-resistant cigarette box?
Contempo Specialty Packaging has created the world's first 100% paperboard, child-resistant cigarette-style box for cannabis pre-rolls, certified under 16 CFR Part 1700 .
Why were traditional cigarette boxes not child-resistant?
Traditional flip-top cigarette boxes have vulnerable tear points that children can exploit during testing, making them accessible .
Is paperboard child-resistant packaging recyclable?
Yes, Contempo's box is available in FSC-certified or recycled paperboard and is described as "easily recyclable" at end-of-life .
Can paperboard packaging accommodate different pre-roll sizes?
Yes, the box size can be fully customized to accommodate different quantities or sizes of pre-rolls .
What finishes are available for paperboard packaging?
The box is compatible with hot stamping, spot UV, soy-based inks, and other premium print finishes .
Are there other companies making paperboard child-resistant packaging?
Yes. Burgopak and Global Packaging have developed an ISO 8317-certified paperboard box with a sliding tray mechanism, and Earthycores manufactures certified paper tubes with airtight sealing .
Does paperboard packaging work with automated filling lines?
Yes, the Burgopak solution is designed for high-speed automated filling lines, ensuring scalability for both craft and industrial producers .
How does this address the single-use plastic problem in cannabis?
By eliminating plastic from the packaging structure entirely, paperboard solutions reduce plastic waste and support circular economy principles
