Custom Plastic Popcorn Boxes

Custom plastic popcorn boxes give cinemas and events a reusable, branded tub that fans keep, refill and carry home. A paper box is used once, but a printed plastic tub becomes walking advertising every time it is refilled. At Apexio Packaging, we make custom plastic popcorn boxes in the USA from food-grade, BPA-free PET and PP for cinemas, sports venues, events and snack brands. With zero MOQ, free design, a free 3D mockup and free US shipping, you can order one tub to check the mould or a full wholesale run and get the same durable, food-safe result. Get your free quote and free 3D design proof today – email sales@apexiopackaging.com or call +1 (855) 466-6990.

What Are Custom Plastic Popcorn Boxes?

Custom plastic popcorn boxes are rigid, reusable tubs moulded in food-grade plastic and branded to survive washing and refilling. Unlike paper, a plastic tub is built for repeat use, so a fan keeps it as merch and refills it at every visit. We mould them in clear or coloured PET and PP, with hinged or snap lids that seal out humidity and keep popcorn crisp. The rigid wall gives a large, wrap-around surface for durable branding that will not smear or soak.

Which Venues Use Plastic Popcorn Tubs

Plastic tubs suit high-traffic venues that reward reuse and brand visibility. Cinemas and sports arenas sell refillable tubs as season merch, theme parks and events use them as souvenirs, and gourmet brands use clear tubs to show a premium product. Because the tub survives dishwashing, it keeps promoting the venue long after the first serving. For a paper alternative in high volumes, compare our large popcorn boxes.

Plastic Popcorn Tub Sizes and Capacity

Tubs are moulded to set capacities, mapped here in ounces and cups to real dimensions.

Capacity	Approx. dimensions (Dia x H)	Typical use
32 oz (about 4 cups)	5 x 5 in	Single-visit serving
64 oz (about 8 cups)	6.5 x 6 in	Standard refillable tub
85 oz (about 10-11 cups)	7 x 7 in	Sharing and family tub
130 oz (about 16 cups)	8.5 x 8 in	Souvenir bucket

Moulded tubs come in set capacities, and we can tool a custom shape or bucket for a signature look. Each holds its volume without flexing, and stacks for storage behind the counter.

Materials and Food-Grade Plastic

Plastic popcorn tubs use food-grade, BPA-free plastic – not paperboard – chosen for reuse, clarity and strength.

Material	Property	Best for
Food-grade PET	Clear, rigid, recyclable	Show-the-product tubs
Food-grade PP	Tough, heat-tolerant	Dishwasher-safe reusables
Coloured PET/PP	Solid brand colour	Team and venue merch
Frosted PET	Soft translucent look	Premium gourmet tubs

PET is clear, rigid and recyclable, so it shows off gourmet popcorn, while PP is tougher and heat-tolerant for dishwasher-safe reuse. Both are food-grade and BPA-free. Because these are reusable plastic tubs, we describe them as recyclable and reusable – not biodegradable – so the sustainability claim stays honest.

Printing and Branding on Plastic

We brand plastic tubs with print methods built to survive washing and handling, not paper inks.

Method	Best for	Main strength
UV printing	Full-colour art on plastic	Vivid, wash-resistant graphics
Screen printing	Bold 1-3 colour logos	Durable, cost-effective at volume
In-mould label (IML)	Photo-quality wrap	Seamless, scratch-resistant finish
Embossed mould logo	Raised brand mark	Subtle, permanent branding

UV and screen printing bond directly to the plastic so the artwork survives repeated dishwasher cycles, while in-mould labels give a seamless photographic wrap. An embossed logo in the mould adds permanent, no-ink branding.

Colour Options: CMYK, PMS and RGB

Plastic tubs print in CMYK and match exact Pantone brand colours, while RGB stays for on-screen design.

Colour system	Use it for	Note
CMYK	Full-colour art, gradients, photos	Standard four-colour print
PMS (Pantone)	Exact logo and brand colours	Identical shade on every reprint
RGB	On-screen design and previews	Convert to CMYK before printing

UV printing reproduces full-colour CMYK art on the tub, while Pantone (PMS) matching locks a team or venue colour across every batch. RGB is converted before print. Our CMYK and Pantone colour guide explains how the shade is confirmed on plastic.

Finishes and Coatings

Finishes set the surface look of a plastic tub and protect the print through repeated washing.

Finish / coating	Effect	Best for
Gloss finish	Bright, glassy surface	Merch and retail tubs
Frosted finish	Soft translucent look	Premium gourmet tubs
Anti-scratch coating	Keeps print sharp	Repeat-use merch
Matte finish	Low-glare premium feel	Boutique brands

A gloss finish gives a bright, glassy tub, frosted softens the look for gourmet lines, and an anti-scratch coating keeps the branding sharp through many dishwasher cycles.

Lids and Add-Ons

Lids and add-ons turn a tub into a sealed, portable, reusable product.

Add-on	What it does	Best for
Hinged or snap lid	Seals in freshness	Take-home and storage
Carry handle	Portable bucket format	Events and souvenirs
Airtight seal	Locks out humidity	Long-freshness tubs
Stackable base	Saves counter storage	High-volume venues

A hinged or snap lid seals out humidity so popcorn stays crisp for take-home, a handle makes a bucket portable, and a stackable base saves space behind a busy counter. For a printed paper alternative, see our custom printed popcorn boxes. Ready to build yours? Get a free quote and a free 3D proof now – email sales@apexiopackaging.com or call +1 (855) 466-6990.

Food Safety: BPA-Free and FDA-Compliant

Plastic popcorn tubs are moulded in food-grade, BPA-free plastic safe for direct popcorn contact. A reusable food container has to be safe wash after wash. We mould tubs in food-grade, BPA-free PET or PP that meets FDA food-contact standards, so they are safe for direct contact with buttered popcorn and top-rack dishwasher-safe. That durability is exactly why fans keep and refill them.

Wholesale Plastic Popcorn Boxes: Zero MOQ and Lead Time

Ordering plastic popcorn tubs stays simple, with zero MOQ, free design and free US shipping. Order a single tub to check the mould, clarity and print, then scale to a wholesale run. Moulded plastic can need a slightly longer lead time than paper, so standard production runs about 5-7 business days after proof approval, with a RUSH option for tight dates. There is no minimum – 100 or more units simply lowers your cost per tub. Pair tubs with our custom take out boxes for full concession service. Order now with zero MOQ and free US shipping – get your free quote today.

Our Quality Review Before Production

We review every plastic tub for clarity, print adhesion, lid fit and food safety before it ships. We check the mould finish, print bond, lid seal and wall strength, and we confirm the tub survives dishwashing without fading or warping. The result is a reusable, branded tub that keeps promoting your venue long after the first serving.

Order Custom Plastic Popcorn Boxes Today

Give fans a tub worth keeping. Start with zero risk: no minimums, free design, a free 3D mockup and free US shipping on every order. Send us your venue, colours and capacity, and our team moulds a food-safe, reusable plastic tub that carries your brand every time it is refilled. Get your free quote now – email sales@apexiopackaging.com or call +1 (855) 466-6990.