Which Box Style is for me?
Below is what we make. The type of box available is dependant on the size you want.
If you are not sure what is the best option, we can help.
Download - Box Styles
"Flap" Boxes
The most common styles of boxes - for shipping and packing. Flaps top and bottom are sealed by tape or staples. Flaps can also overlap or all meet to provide increased support to the contents. "Reverse Flute" versions have long depths and can be laid sideways with optimal strength. Height or depth cannot go below 80mm nor can the width.
Regular Flap
Tape sealed flaps, top and bottom, that meet in the middle. The most used box style. Can be made from one sheet and glued on the depth. If the size is too big for one sheet it can be made from two or fours sheets and glued or stapled together.
Full Flap
Tape sealed flaps, top and bottom, that overlap to each box side. The overlapping flaps adds support to the top and bottom of the box. This box style can also be made in the "reverse flute" style. Can be made from one sheet and glued on the depth. If the size is too big for one sheet it can be made from two or fours sheets and glued or stapled together.
Regular Flap/Full Flap - Reverse Flute
A good choice for boxes with short length and width dimensions and longer depths. EG 100x100x600mm. Suites products such as rolled up posters. A good alternative to postal mailing tubes. What makes this style special is the "flute" is reversed. (see the FAQ page for an explanation on "reversed flute") When the box is laid sideways the box has optimum stacking strength, unlike a normal flapped box. Available where the outside flaps meet in the middle (Regular Flap) or overlap completely (Full Flap).
Flaps to Meet
Tape sealed flaps, top and bottom, that meet in the middle. Inside flaps also meet in the middle. Provides extra security. Good for products requiring a flat bottom, like candles. More expensive than the Regular Flap or Full Flap styles. (The length must be 86mm longer than the width)
Variable Flap
Tape sealed Flaps, top and bottom. This style gives you added security because the flaps overlap thus increasing the stability and strength. The negative can be that the box does not sit flat on the ground. You specify how much an overlap you want.
"Flat Pack"
Boxes
Boxes that are more short and flat - Suites flat pack furniture, artwork or picture frames, displays and printers. Best for boxes that are short in height and long or wide. All these box styles wrap around the contents and are sealed with tape, glue or staples. Minimum depth is 40mm; with the exception of the One Panel Folder, which has a min. depth of 5mm.
Full Flap Five Panel Folder - Hinged Length
Best for boxes of short depths. From 40mm up to 150mm is good. A “flat pack” style of carton. Not glued. Overlaping flaps on one long and two short sides. Hinged on one length dimension. The outer overlapping flaps give the box extra load strength. To seal the box, place the contents in the box, fold the box and apply tape after the box is assembled. The width has to exceed twice the depth for the inside flaps to not overlap.
Centre Fold Full Flap Five Panel Folder
Best for boxes of short depths. From 40mm up to 150mm is good. A “flat pack” style of carton. Not glued. The box is folded into the centre, making it easier to assemble than the Full Flap Five Panel Folder. The width has to exceed twice the depth for the inside flaps to not overlap at the ends. Not as strong as the Full Flap style or as secure but it is cheaper. To seal the box, place the contents in the box, fold the box and apply tape after the box is assembled.
Full Flap Five Panel Folder - Hinged Width
An alternative to the Full Flap Five Panel Folder. From 40mm up to 150mm is good. Not glued. Overlaping flaps on one short and two long sides. Hinged on one short dimension. The overlapping flaps give the box extra load strength. It is like a FF5PF but provides extra stacking strength on the long dimensions. To seal the box, place the contents in the box, fold the box and apply tape after the box is assembled. Note - this style is not a 'die cut' and does not have locking tabs, like a pizza box. The Length has to exceed twice the depth to avoid the inside flaps overlapping.item about?
One Panel Folder
This style is for boxes with shallow depths. Available from a depth of 5mm up, it becomes much less costly above 40mm in depth. Good for books. Hint: Reduce the length flap, inside, to reduce the cost. But, it lowers security. Default is for all flaps to meet. Extra Scores are from the base of the box up.
One Panel Folder - Air Cell
This style is for boxes with shallow depths. It also provides added side protection to the box contents. Available from a depth of 40mm up. Good for books.
"Open Top"
Boxes
These boxes have no top. One is sealed with tape on the bottom and the other has side flaps which require staples or glue to hold together the box.
Half Flap
Open top Box. Tape sealed flaps on the bottom, that meet in the middle. Can be made from one sheet and glued on the depth. If the size is too big for one sheet it can be made from two or fours sheets and glued or stapled together. Minimum depth of 80mm.
Tray, Scored & Slit
Open top box style. Best used when the depth is small, from 40mm upwards. The box will need to be glued or stapled when it is assembled by the user prior to use.
Inserts
The purpose of inserts is to provided additional protection for items packed in boxes.
Pad
Flat cardboard, to provide support, in the bottom or to separate items in a box.
Scored Pad
Pads, scores added to allow you to fold them. Can be used as a simple, and effective, alternative to the difficult to assemble dividers.
Sleeve
Provides additional stacking strength and goes inside a regular box. Open top & bottom. Can be made from one sheet and glued on the depth. If the size is too big for one sheet it can be made from two or fours sheets and glued or stapled together.
Roll Up
A simple way of adding extra security to your product. It goes between the product and the outside box, to add a buffer from impact. Minimum width of 40mm
Air Cell
For use inside a shipping box to add extra protection. The Aircell dimension minimum is 45mm.
"Box & Lid"
Boxes
Open top boxes with a separate lid. Often of a larger size, up to pallet size.
B&L - Trays and Sleeve
This style is suited for big boxes. The item is placed in a tray then a sleeved placed over it and another tray placed on top. You assemble the trays with either a glue gun or staple gun. You can change the board grade of the lid. Hint: Suggested depth of the tray - 100 to 200mm.
B&L - Tray & Tray
Good for Artists, Photographers, Picture Frame makers. This style is suited for boxes with short depths. You assemble the trays with either a glue gun or staple gun. You can change the board grade of the lid.
B&L - Half Flap and Tray
A combination of the half flap and tray styles. You can make either style the base and the other the lid. Eg you make the tray, put your product in, then put the half flap on top, or do it the other way round. This style is suited for larger depth boxes. You use the tray if you only want smaller depth. You can change the board grade of the lid. Hint: Suggested depth of the tray - 100 to 200mm.
B&L - Half Flap and Half Flap
A combination of the half flap and half flap styles. You can make either style the base and the other the lid. Eg you make the tray, put your product in, then put the half flap on top, or do it the other way round. This style is suited for larger depth boxes. You can make the lid depth as deep as the base depth. You can change the board grade of the lid.
Box & Lid - Tray, Tray & Air Cell
High strength box combination. A combination of two trays and and air cell. Provides optimal strength and protection. Width needs to be twice the depth. Depth should be no more than 200mm
