Calculate Inner Alu-Foil Roll Width & Outer 3D BOPP Overwrap Dimensions
Calculate inner pillow-foil parent web width (`<=350 mm`) for 50g, 100g, and 250g extruded shisha bricks, plus outer 3D carton BOPP film width and cutoff pitch.
Contents in This Guide
Geometry Rules Linking Compressed Shisha Density (~0.85–1.05 g/cm³) to Carton Fit
Extruded shisha molasses compacts to roughly 0.85–1.05 g/cm³ bulk density—meaning a 50 g foil brick occupies ~48–58 cm³ (e.g., 78 × 48 × 15 mm), while a 250 g brick occupies ~240–285 cm³ (e.g., 125 × 78 × 28 mm). Grounded in shisha line sizing and guides and molasses rheology and barrier specs, inner pillow-foil web width and outer 3D carton overwrap film follow two exact formulas:
Inner Foil Web (BS-350XL): Foil_Width_mm = 2 × (Brick_Width + Brick_Height) + 28_mm_Fin_Seal.
Outer 3D Box BOPP Film: BOPP_Width_mm = Carton_Length + Carton_Height + 18_to_24_mm_Fold, and BOPP_Cutoff_mm = 2 × (Carton_Width + Carton_Height) + 22_mm_Lap.
Standard Commercial Shisha Brick, Carton & Film Reference Table
Published dimensions for industry-standard 50 g, 100 g, 250 g, and 10-pack formats:
| Retail Format | Typical Carton (L×W×H mm) | Inner Foil Web (mm) | Outer BOPP Web × Cutoff | Machine Fit |
|---|---|---|---|---|
| 50 g Pocket Carton | 86 × 54 × 18 mm | 156–165 mm (BS-350XL) |
124 × 166 mm (+ tear tape) | Standard 50g retail |
| 100 g Mid Carton | 105 × 65 × 24 mm | 205–215 mm (BS-350XL) |
150 × 200 mm | Travel / mid-tier |
| 250 g Brick Carton | 138 × 85 × 34 mm | 265–280 mm (BS-350XL) |
194 × 260 mm | Classic 250g box |
10 × 50g Sleeve (5×1×2) |
272 × 174 × 38 mm | N/A (collated boxes) | 334 × 446 mm clear BOPP | 500g duty-free brick |
Inspect inner brick extruder specifications in 2-in-1 molasses extruding and pillow wrappers.
Molasses & Barrier Engineering Notes
- Leave 3–4 mm Internal Carton Clearance Around Foil Bricks: Foil end-crimps fold against brick ends—sizing the paperboard carton
3–4 mmlonger and2 mmthicker than the raw extruded brick prevents bulging box flaps before 3D overwrapping. - Self-Adhesive Gold/Red Tear-Tape Placement: Standard 1.6–2.0 mm mono-oriented polypropylene tear tape applies cross-web or inline with a precision die-punched easy-grip starter tab.
- Verify BS-350XL Max Web (
350 mm) on 500g–1kg Bricks: Bricks wider + taller than155 mm(W + H > 155 mm) require a wide-frame450/500 mmwrapper rather than a standard350 mmhead.
Confirm Foil & Carton Dielines Before Printing Cylinders
Share your proposed box L × W × H mm and target gram weight via Project Brief.
Compare related architectures in Shisha Packing Machines, Molasses & Barrier Specs, or submit your target pack weights via Project Brief.