Looking at this: https://www.thegamecrafter.com/publish/product/PokerTuckBox54.
Using the example of a 20 page booklet, would I only be able to fit 50 cards maximum in the pack?
If I have a game with 54 cards and I wanted a 20 page booklet, is there an option for a tuckbox that would fit everything?
Yep, 50 would be the ideal amount of cards with the 20 page rulebook. Some people try and stuff a few more cards in our tuck boxes but we don't advise that because as you shuffle the cards over time they will expand a bit. It's nice to have a little wiggle room. I do know other designers have done this though.
Your options would be to either try to squeeze in the extra 4 cards like they do or move up to the 72-card tuck box. The 72 card box won't be entirely full with only 54 cards + 20 page booket and that can lead to decreased strength and durability of the box since it gets it's rigidity from the contents inside of it.
Thanks. Related question, if I placed an order for 100 50 Card sets, 100 20 page booklets, and 100 tuckboxes, does the order come shipped with a set of cards and 1 booklet inside each tuckbox, or is everything seperate?
If you create a game that contains a tuck box, a card deck, and a booklet, then order 100 copies of your game, each set will come with the cards and booklet in the box and the box shrink-wrapped.