Folding Carton Box Packaging – The Master Guide

Types and styles of folding carton packaging materials

The most popular materials used in the production of standard folding cartons are paperboards made from wood pulp, a renewable and eco-friendly resource. However, there are more advanced, certified paperboards that can be used for food and medical applications.

To make it even more eco-friendly, kraft paperboard made from 100% post-consumer recycled material or reclaimed paper stock is also a popular choice. And if you thought the range of materials was extensive, there is also a wide variety of styles and types of box. In this master guide, we present the seven most popular styles.

The crash bottom box, also known as the tuck end auto-lock bottom box, has a bottom that automatically locks into place with a simple tuck flap. This box is ideal for heavy products such as wine and beer because it is the most robust of all the paper box packaging listed below.

Another option is the snap bottom or lock bottom box, which is also strong and can be used to store heavy products such as wine or electronics. This style of box is also referred to as the '1-2-3' bottom box because the flaps are pushed inwards and clamped.

Straight tuck end boxes are flat-packed and do not require assembly. They are characterised by the top and bottom closures being on the same side of the box, with slits in the ends to hold the tucks in place. This style is best suited to light or medium-weight products, such as cosmetics or essential oils.

Reverse tuck end boxes are identical to straight tuck end boxes, except the end closures are on the opposite side of the box. Reverse tuck boxes are also suitable for light- or medium-weight products, as they are almost identical.

Paper sleeve packaging is a type of carton designed to slide over a plain box. It is a highly popular option because it is the cheapest and can instantly customise a plain box.

Two-piece boxes, also known as double-wall tray-and-lid boxes, are divided into a top and bottom half. The tray and lid fit together perfectly to form a robust double wall, making them ideal for packaging luxury products such as jewellery and clothing, or for use as food packaging for products such as confectionery.

The latest trend is customised folding carton boxes. Who said foldable cartons had to be like that? The above options have custom cut-outs and inserts, the possibilities for which are limited only by the imagination. Inserts or cut-outs can be placed in strategic spots to give your packaging a special flair that sets it apart from competitors' packaging!

The styling possibilities are endless, whether you choose paper food packaging with folding cartons or packaging for other products, such as cosmetics and electronics. Whether you choose kraft paper packaging because it is environmentally friendly or a two-piece box to add luxury, these foldable paper boxes are a great choice for any product!

Manufacturing processes

No matter what materials or style you want to use for your carton packaging project, the process of creating folding cartons remains the same. Once you have finalised the design of your box, it is time to leave your packaging supplier to work through the following detailed processes, collectively known as 'converting'.

1.Die lines and sheet layout: Die-lines are two-dimensional representations of the box, showing what the final 3D box will look like. They show where the die-cutting, folding and gluing will occur, as well as the position of the artwork on the finished package.

2.Sheeting and printing: Paperboard is cut into large rolls, which are then cut into sheets and subjected to the printing press. At this stage, manufacturers ensure that the grain runs in the most efficient and effective direction. Once the sheet goes to the printing press, the imagery and artwork you designed will be inked and applied to the sheet using offset, digital or flexographic printing techniques.

3.Post-press finishes: Additional customisation options, such as hot-foil stamping, embossing or debossing, can be performed on specialised equipment at this stage to enhance the appearance of your box.

4.Die-cutting: Numerous duplicates of your carton are cut out of the paperboard sheet at this stage. The die is a specialised cutter, similar to a cookie cutter, which cuts the paperboard with minimal waste and allows for easy folding where required. The manufacturer recycles the surplus paper scraps produced at this stage into new paperboards.

5.Folding and gluing: This is the final step in the conversion process, during which your box is fed through a machine that folds, pre-breaks and glues the flat, die-cut pieces. Certain cartons featuring transparent windows are incorporated at this stage. The manufacturer will strive to complete these processes in as few passes as possible.