Boxed lunches look like easy money. They are not.
Packaging, cookies, and “free” chips turn a simple sandwich into a margin trap. Corporate customers push for round numbers and volume discounts, so you need a clear per-box cost before you quote.
This guide gives you a US boxed lunch cost calculator with itemized math, packaging add-ons, and pricing targets that protect your margins.
Quick Summary
- Cost each box by component (main + side + dessert + drink + packaging)
- Add packaging cost per box (not per order)
- Quote volume discounts only after you see the bundle food cost %
- Use public price benchmarks to sanity-check key items
Why Boxed Lunch Pricing Fails
- Packaging is real cost. Boxes, labels, and cutlery add $0.40-$1.20 per box.
- “Free” sides are not free. Chips, fruit, or cookies add 10-20% to food cost.
- Delivery fees kill margin. Per-order fees lower the blended margin fast.
- Round-number pricing hides error. $12.00 looks good until your cost is $4.10.
- Discounts are sticky. Once a client sees a low price, they expect it forever.
The Core Boxed Lunch Cost Formulas
Usable amount = Purchase weight x (1 - loss rate)
Unit cost = Price / Usable amount
Item cost = Unit cost x Portion amount
Box cost = Main + side + dessert + drink + packaging
Food cost % = Box cost / Box priceIf a denominator is 0, treat the cost as 0. If the result is NaN or Infinity, set it to 0 and fix the inputs.
US Price Benchmarks (Retail, City Average)
These are U.S. city average retail prices from BLS average price data (via FRED). They are not wholesale, but they are a sanity check.
| Item | Latest price | Unit cost | Why it matters |
|---|---|---|---|
| Bread, white, pan | $1.833/lb (Dec 2025) | $0.11/oz | Base of every sandwich box |
| Chicken breast, boneless | $4.153/lb (Dec 2025) | $0.26/oz | Premium sandwich protein |
| Eggs, Grade A, large | $2.712/dozen (Dec 2025) | $0.23/egg | Egg salad and breakfast boxes |
| Lettuce, iceberg | $1.731/lb (Sep 2025) | $0.11/oz | Sandwich and salad filler |
| Tomatoes, field grown | $1.840/lb (Dec 2025) | $0.12/oz | High-use topping |
Conversion:
Price per oz = Price per lb / 16Use these as directional signals, then plug in your invoices.
Step 1: Build a Box Cost Card
Every boxed lunch should list:
- Main (sandwich, wrap, or salad)
- Side (chips, fruit, or salad)
- Dessert (cookie or brownie)
- Drink (bottled or can)
- Packaging (box, utensils, label)
If you cannot list all five, you will under-price the box.
Example #1 — Classic Deli Sandwich Box
Portion assumptions:
- Bread: 2.5 oz
- Turkey: 3 oz
- Cheese: 1 oz
- Lettuce/tomato: 2 oz
- Condiments: $0.12
- Chips: 1 bag
- Cookie: 1
- Bottled water: 1
- Packaging: $0.75
| Item | Portion | Unit Cost | Line Cost |
|---|---|---|---|
| Bread | 2.5 oz | $0.11/oz | $0.28 |
| Turkey | 3 oz | $0.34/oz (example) | $1.02 |
| Cheese | 1 oz | $0.36/oz (example) | $0.36 |
| Lettuce/tomato | 2 oz | $0.12/oz | $0.24 |
| Condiments | — | — | $0.12 |
| Chips | 1 bag | $0.45 (example) | $0.45 |
| Cookie | 1 | $0.38 (example) | $0.38 |
| Bottled water | 1 | $0.40 (example) | $0.40 |
| Packaging | — | — | $0.75 |
| Total box cost | $4.00 |
Price targets:
| Target Food Cost % | Box Price |
|---|---|
| 30% | $13.33 |
| 32% | $12.50 |
| 35% | $11.43 |
Suggested price range: $11.99-$13.99
Example #2 — Chicken Salad Box
Portion assumptions:
- Salad greens: 4 oz
- Chicken: 4 oz
- Tomato/cucumber: 3 oz
- Dressing: 2 oz
- Side fruit cup: 1
- Cookie: 1
- Bottled water: 1
- Packaging: $0.85
| Item | Portion | Unit Cost | Line Cost |
|---|---|---|---|
| Salad greens | 4 oz | $0.12/oz (example) | $0.48 |
| Chicken | 4 oz | $0.26/oz | $1.04 |
| Tomato/cucumber | 3 oz | $0.12/oz | $0.36 |
| Dressing | 2 oz | $0.12/oz (example) | $0.24 |
| Fruit cup | 1 | $0.70 (example) | $0.70 |
| Cookie | 1 | $0.38 (example) | $0.38 |
| Bottled water | 1 | $0.40 (example) | $0.40 |
| Packaging | — | — | $0.85 |
| Total box cost | $4.45 |
Target price at 32% food cost: $13.91
Suggested price range: $13.49-$14.99
Example #3 — Wrap + Side Box
Portion assumptions:
- Tortilla: 1
- Chicken: 3 oz
- Cheese: 0.7 oz
- Lettuce/tomato: 2 oz
- Side salad: 4 oz
- Cookie: 1
- Drink: 1
- Packaging: $0.80
| Item | Portion | Unit Cost | Line Cost |
|---|---|---|---|
| Tortilla | 1 | $0.35 (example) | $0.35 |
| Chicken | 3 oz | $0.26/oz | $0.78 |
| Cheese | 0.7 oz | $0.36/oz (example) | $0.25 |
| Lettuce/tomato | 2 oz | $0.12/oz | $0.24 |
| Side salad | 4 oz | $0.12/oz (example) | $0.48 |
| Cookie | 1 | $0.38 (example) | $0.38 |
| Drink | 1 | $0.40 (example) | $0.40 |
| Packaging | — | — | $0.80 |
| Total box cost | $3.68 |
Target price at 30% food cost: $12.27
Suggested price range: $11.99-$12.99
Volume Discount Math (Use a Spreadsheet)
Before you offer a volume discount, calculate this:
Discounted box price = List price x (1 - discount %)
New food cost % = Box cost / Discounted box priceIf the food cost % jumps above your target by 3-4 points, the discount is too deep.
Packaging Checklist for Boxed Lunches
- Box or clamshell
- Label
- Utensils + napkin
- Sauce cup
- Bag (if required)
Packaging is not optional. Add it to every cost card.
Monthly Corporate Catering Routine
- Re-cost your top 5 boxes
- Check packaging costs (they creep fast)
- Review delivery fees and minimums
- Adjust list price before the next client renewal
Boxed Lunch Cost Checklist
- Box cost card updated monthly
- Packaging counted per box
- Volume discounts tested with math
- Delivery fees included in quotes
- Protein portions standardized
Related Guides
- Catering Cost Guide
- Catering Pricing Guide
- Sandwich & Deli Cost Guide
- US Coffee Shop Cost Guide
- US Menu Pricing Calculator
- Chicken Restaurant Cost Guide
- Home Baking Pricing Guide
- Bunsik Cost Guide
- Pizza Cost Calculator
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