All About Boxes

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We understand that packaging forms a vital part of your business logistics.

We use our expertise to advise customers on the most effective and efficient packaging solutions for their specific requirements, ensuring your goods arrive in despatch condition.

 

Cardboard boxes are one of the core products in the packaging industry for transporting your products to the customer.

With sustainability in the forefront of our minds cardboard ticks the box as it is manufactured from paper pulp with a high percentage of recycled material and is 100% recyclable.

 

Fluted Cardboard

Fluted cardboard is made up of a fluted layer of paper sandwiched between two liners. These layers are manufactured from recycled paper. Often the outer liner is manufactured from kraft, which is a virgin paper to make the box stronger.

 

Single Wall has one layer of fluted card.

Double Wall has two layers of fluted card.

Fluting Sizes:

E-Flute                   1 – 1.8mm

B-Flute                   2.1 – 3mm

C-Flute                  3.2 – 3.9mm

EB-Flute                3. – 3.7mm

BC-Flute               5.3 – 6.5mm

Board Grades
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Board Grades

Choosing the right board grade for your products

 

Cardboard is made up of layers of card. Each layer has a different weight/thickness (gsm) and is manufactured from different material.

Kraft is the term used for virgin paper and Test is the term used for recycled paper. The inside layer of a box is normally a Test liner and the outside is normally a Kraft liner. Some boxes are manufactured with a Test liner on the outside. This is normally a higher quality liner to maintain stability. The fluting is Test.

 

The most popular board used in cartons is B-Flute for a Single wall box and BC-Flute for a double wall box.

As a guide based on a regular sized carton eg 450 x 300 x 300mm the following board grades can be considered

Single-wall board. ‘B’ or ‘C’ flute

Double-wall board. ‘B/C’ flute

Grade

Contents weight

125 Kraft/Test

5 Kg

150 Kraft/Test

10 Kg

200 Kraft/Test

15 Kg

200 Kraft/ 300 Test

20 Kg

300 Kraft/Test

30 Kg

Grade

Contents weight

125 Kraft/Test

15 Kg

150 Kraft/Test

20 Kg

200 Kraft/Test

30 Kg

200 Kraft/ 300 Test

35 Kg

300 Kraft/Test

40 Kg

How to measure a box

  1. The first dimension to measure is the length. The length is always the longest side of the box on the opening.
  2. The next dimension is the width. The width is the shorter side on the opening.
  3. The last dimension is the height. The height is the “floor to ceiling” measurement when the opening is at the top.

When measuring a box to fit an item we recommend you add 5mm to the item dimensions for the box dimensions.

This will allow for manufacturing tolerances when creasing, slotting and die cutting.

 

SAMPLES

If the sizing is critical to a fine tolerance we would strongly advise a sample for testing purposes.  Often samples are cut on a CAD cutter and the edges are crisp and sharp. The production run may not be the same on a regular carton due to high production speeds.

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Box Styles

There are many different styles of boxes available. The manufacturing process varies depending on the style making some styles more popular than others.

 

All the available styles available are listed in the FEFCO listings which are available to download.

 

Download FEFCO style list.

 

The most popular styles used in shipping and eCommerce are listed below. Some of these styles are die cut and require tooling prior to being manufactured.

 

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0201 Box

Of all the styles available the most popular by far is the 0201.

The 0201 is the standard style packing box

Double-Wall-Stock-Carton

The 0201 box, often referred to as a shipping box or  RSC (regular slotted carton), is the most popular of all the styles available. This is due to the fact they can be manufactured in small and large dimensions with short, medium and high volume runs, at high speeds.

Printing is an option that is applied either in-line as part of the manufacturing process or digitally overprinted for short runs.

There are two types of joint on an 0201 box. Glued and Stitched.

A glued joint is the normal method that would be used if not specified. The stitched method would normally be used for heavier items and would need to be specified at the time of order. The stitched boxes generally cost more as the manufacturing process is slower.

Multi-Depth Box

When manufacturing 0201 style boxes, extra creases can be added to create a vari-depth box. This helps reduce the amount of packing filler required giving greater load stability.

 

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eCommerce

Ecommerce packaging demands are greater than ever before with 95% of British people now buying goods via internet retailers

 

With an increase in eCommerce sales the unboxing experience is of all the more importance to strengthen the power of your brand.

eCommerce boxes are available in many different styles and board grades. The most popular eCommerce box is the 0427 style in white or brown board, printed with you brand message on the inside, outside or both.

 

To make your pick and pack operation more effective peel-and-seal strips can be added along with tear strips.

All eCommerce boxes are die cut and require tooling and print plates if printing is required. This all comes at a cost but if the order quantities are medium to high it is a very small percentage of the unit price.

If you have an ongoing requirement then you may be interested in our bulk order scheduling call off order system.

For short run printed eCommerce boxes, we are able to digitally overprint a box cut from stock tooling.

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