Corrugated Box Design

Corrugated Box Design

More than 95% of all products in the United States are shipped in corrugated boxes because it is affordable, versatile, environmentally friendly, and provides great protection. Corrugated packaging is generally considered the most economical type of packaging. Custom printed boxes are an inexpensive and effective way to enhance your company’s brand, attract attention, and grow awareness.

Most corrugated boxes are made from single wall or double wall corrugated. Single wall corrugated consists of one layer of fluting (also referred to as medium) in between two layers of linerboard. Double wall corrugated consists of two layers of fluting and three layers of linerboard. The 5-ply construction offers a great deal of strength and extra padding for especially heavy or fragile items.

Fluting is simply the wavy looking paper that is sandwiched between the two linerboards that gives corrugated boxes its strength and protection attributes. Different flutes are combined when making a double wall box to take advantage of their different properties.

Corrugate Manufacturing Diagram from PAX Solutions
Corrugated Box Fluting Chart from PAX Solutions

Packaging for every product.

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Corrugated Box Design

Corrugated packaging is extremely versatile and can come in various shapes / sizes to meet almost any shipping need.

In order to start the design process, we first need to understand the shipping environment and risk of product damage. For more fragile products, we can help design a corrugated box with maximum protection to ensure your products arrive safely. For less fragile products, we can change our focus to operational efficiencies and overall cost reduction.

Additionally, we are able to print the boxes several colors and add your business logo, name, tagline, or any other identifying information on the box.

Below are a couple of examples of the most popular corrugated boxes. However, we have the technology and tools to create anything you can imagine.

Regular Slotted Container (RSC)

The Regular Slotted Container (RSC) is 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.

Regular Slotted Container Box from PAX Solutions

Full Overlap Container (FOL)

The FOL has flaps that extend and overlap each other covering the entire opening of the box. FOL boxes can be ordered with flaps just on top, just on the bottom, or on both top and bottom. This style provides additional strength to the ends of the box and can allow for easier assembly when dealing with smaller shipping boxes.

Full Overlap Container from PAX Solutions

Die Cut Front Tuck Shipper

Die cut shippers require special tooling (referred to as cutting dies) to be manufactured. Different options are available depending on the project. The most common option is the front tuck shipper. This is a versatile shipping box that provides great protection. After the boxes are cut, they can be further customized by adding unique graphics or inserts to present the product.

Die Cut Front Tuck Shipper from PAX Solutions

One Piece Folder (OPF)

The One Piece Folder (OPF) box is an ideal shipper for flat items with shallow depth such as books, marketing kits, and other media. This style features a single piece of corrugated with a flat bottom, end flaps, and side flaps that fold over and meet to form the top of the box.

One Piece Folder from PAX Solutions

Full Telescope Design (FTD)

FTD cartons consist of a separate top and bottom that fit over each other with flaps joining on the side or end panels. When pulled apart, they create two scored and slotted trays, both with flat bottoms. The full-depth cover slides completely over the body of the carton providing additional strength around the sides making this style suitable for high stacking strength of fragile articles.

Full Telescope Design from PAX Solutions

Environmentally Friendly

Not only is corrugated packaging easily recyclable and renewable, but it can also be reused as is, helping to further reduce packaging costs and the environmental impact. Many corrugated case styles are designed to be easily collapsible and fully reusable.

Another benefit of corrugated packaging having a high percentage of recycled components is that it requires less energy to make.

Rather than producing cases from 100% virgin materials, most corrugated manufacturers make products from locally sourced recycled content—which also minimizes environmental damage caused by excessive transportation.

Circular Fiber Flow from PAX Solutions

Contact us today to discuss your corrugated box needs!