A box with unique curves or cut-outs, or with personalized color or printing CAN be considered a customized box, but, in fact, the term "custom box" is used to designate a specially made corrugated box that is not mass produced at a standard size. Box dimensions are always inside dimensions and must be stated in the sequence of length, width and depth. The length is always the larger of the two dimensions of the open face (flap opening); the width is the smaller. The depth is always the distance perpendicular to the length and width, and is measured from the inside of the box.
The most common box style used for shipping and storage. The two outer flaps of an RSC box meet at the center of the box when folded and are usually closed using tape, or staples. Where the product requires additional protection over the top or bottom, corrugated pads can be placed between the inside flaps.
Available with tuck-in top or with RSC-style top flaps (shown). The bottom of the box snaps into place without tape for quick assembly. Best suited for light-weight products.
Ideal for boxes with relatively narrow widths. The outer flaps overlap the full width of the box making it especially resistant to rough handling. And, the extra thicknesses of corrugated material on the top and bottom panels provide added stacking strength.
Partial Overlap Carton (POL)
All flaps have the same length. The outer flaps overlap by one inch or more. The box is easily closed, usually with staples through the overlap area. This style is used when the length of the box is considerably greater than the width, resulting in a long gap between the inner flaps. The sealed over-lap helps to keep the outer flaps from pulling apart.
Frequently used for both shipping and shelf storage, and in applications where the cover must be removed and replaced frequently. The top of the HSC box is a tray style which usually extends less than 2/3 the depth of the bottom (PHSC), but can be made to extend the full depth of the bottom (FHSC) if extr strength is needed.
Can be made with either a Full telescope top (FTHS), or a Partial telescope top (PTHS). The two thicknesses of material at the sides and ends of a FTHS box provide maximum protection for the box's contents as well as giving the box superior stacking strength. And, the top is easily removed for examining the contents.
Made from one piece of material and has a flat bottom with flaps that form the sides and ends. The outer flaps meet at the center to form the top. OPF's can be made with multiple scores so that one box can be folded to make up to three different size boxes. The OPF is used principally for shipping books, catalogs, videos, and similar items. OPF's are easy to store, set up, and close.
Is perfect for shipping very long products. Because the FPF has several thicknesses of material on each end, it has a particular advantage when used for packaging long articles of small diameter which might be readily damaged if forced through the ends of the box.
A Die-Cut Mailer is available with or without dust flaps. The box is folded up and the sides lock into place with locking tabs. This box style is generally used to package smaller products and is multi-purpose.
Trays have an unbroken bottom with no top and are generally not used as a shipping container on their own. Flaps on slotted trays are taped or stapled by the end user to form the sides of the container. Die cut 4-sided locking trays have self locking tabs on the side flaps for easy assembly. Trays are often used for produce items, storage, or as elements of display stands.
DST - Design Style Tray
RET - Roll End Tray
RST - Roll Side Tray
Pad / Sheet
A flat piece of corrugated with or without scores. Among its many functions, pads are often used as an added layer of protection, to separate products or layers of product, to cover pallets, or as a space filler.
SCORED PADS - Are used to create custom inner packing. Scored Pads can have up to nine score lines to create many different shapes for keeping products from moving inside a box. Scored Pads such as corner pieces, angles, etc. can be made to fill almost any space to firmly hold products in place during shipping.
Inserts / Dividers
Inserts may take many shapes and are generally used for supporting, cushioning, or separating product in a master carton. This inner packaging may also be used to suspend product or to fill space. Dividers are used to create separate compartments within a larger box to protect small or delicate products.
D/C - Die Cut Pad / Inserts
Board Types
Mullen "Burst" Test
Box strength is measured in two different ways. The mullen test measures resistance to rupture in pounds per square inch (psi). Linerboard constitutes the bulk of the bursting strength of a corrugated sheet. The basis weight of the paper as measured in lbs/1000 sq. ft. directly impacts paper strength. Burst strength is more relevant when product containment or puncture resistance is the main concern. Back to Top
"C" Flute cardboard has a very high stacking strength and a higher resistance to being crushed. It is one of the most commonly used flutes for shipping boxes and tends to perform the best when holding materials such as glass, furniture and food products.
"B" Flute cardboard is the perfect combination of strength and style. It has a higher resistance to punctures than the other flutes and usually consumes less space than the regular "C" Flute. It is most often used for boxes that have to be durable but also need to have some style. Generally used for stand up displays or ballot boxes.
"E" Flute is a stronger alternative to paperboard and performs great when used for die cut designs. "E" Flute has a superior printing surface and works best when used as software packaging or point of purchase boxes.
Designation
Flutes Per Lineal Foot
Thickness
"C" Flute
39 +/- 3
3/16"
"B" Flute
47 +/- 3
1/8"
"E" Flute
90 +/- 4
1/16"
"A" Flute
33 +/- 3
1/4"
"F" Flute
128 +/- 4
1/4"
Double Wall
"See Flute"
5/16"
Triple Wall
"See Flute"
9/16"
Mullen Test
Max Total Weight of Box & Contents
Maximum Dimensions (L + W + D)
ECT Equivalent
125T
20 lbs
40"
23
150T
35 lbs
50"
26
175T
50 lbs
60"
29
200T
65 lbs
75"
32
250T
80 lbs
85"
40
275T
95 lbs
95"
44
350T
120 lbs
105"
55
200T DW
80 lbs
85"
42
275T DW
100 lbs
95"
48
350T DW
120 lbs
105"
51
Edge Crush Test (ECT)
Measures the ability of combined board to sustain a top-to-bottom load. The strength is directly related to the compression strength of both the liners and medium. ECT is more relevant when stacking strength is the main concern. ECT is more relevant when stacking strength is the main concern. Back to Top
Edge Crush Test
Max Total Weight of Box & Contents
Maximum Dimensions (L + W + D)
Mullen "Burst Test" Equivalent
23 ECT
20 lbs
40"
125T
26 ECT
35 lbs
50"
150T
29 ECT
50 lbs
60"
175T
32 ECT
65 lbs
75"
200T
40 ECT
80 lbs
85"
250T
44 ECT
95 lbs
95"
275T
55 ECT
120 lbs
105"
350T
42 ECT
80 lbs
85"
200T DW
48 ECT
100 lbs
95"
275T DW
51 ECT
120 lbs
105"
350T DW
Printing
Flexography
Also known as direct print, flexo printing is the most widely used printing process. Economical for both small and large press runs, and for simple graphics and pleasing color, it is often just what you need. Back to Top
Advantages of Flexo Printing:
It is cost effective for many applications.
It enables faster turnaround time.
Flexo has the ability to print a wide range of inks, including flourescents and metallics.
1 - 3 Color Print
It uses resilient rubber or photopolymer image carriers that can print millions of impressions.
Litho Lamination
Litho lamination combines the strength of corrugation with the appeal of high quality lithographically printed sheets or pre-printed rolls. This process results in very high quality printing and is generally used for high-end retail packaging.
Advantages of Litho Lamination:
Litho lamination offers the consistent high quality of offset printing, much tighter registration and better quality than flexography, and much finer screens and halftones than screen printing
Up to 6 Color Process Print
Appropriate for medium-sized production runs
Digital Printing
Graphics from a digital computer file are transmitted directly to a printer that plots the graphics onto the corrugated board. This eliminates the need for printing plates making short run jobs more cost effective. Digital corrugated printing is ideal for those projects requiring fast turnaround. Back to Top
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