Box Basics - Boxmaster

Box Basics - Boxmaster
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Half Slotted
Die Cut Custom
Containers
These are custom corHalf slotted containers
rugated boxes devel-
are similar to regular
oped to exact specifi-
slotted containers ex-
cations depending on
cept that they have
customer requirements. Boxmaster can
only one set of flaps.

The opposite side of
manufacture custom
the box is open, which
boxes with FULL color,
allows it to slide over
available in all styles
an item. Ideal for: large
and custom sizes.
and heavy objects
Ideal for: unique prod-
such as refrigerators
ucts with special re-
and washing ma-
quirements such as
cosmetic product
chines.
boxes, toy product

boxes, gift product
boxes.
Full Over Lap
Roll End Tuck Top
The outer flaps overlap

the full width of the box
These are simple

unglued boxes that
making it especially re-
need to be folded when
sistant to rough han-
assembled. These are
dling. All flaps are the
great for shipping nar-
same depth, and their
row items. Ideal for: vi-
depth equals the width
tamin packaging, retail
of the box. Ideal for:
packaging, coffee
heavy objects that require extra support
packaging, tea packaging.
such as refrigerators
and washing machines.
Corrugated Box Flute Types

Corrugated Box Construction
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Types of Printing Methods

Printing
Description
Advantages
The most basic type of printing

on corrugated.
Allows the addition of company or

package content info to the surface of the
Method
Flexo Line
box, at a relatively low cost. Graphics

tend to be basic line art and text, utilizing
between 1 and 3 colours.
Flexo Process
Flood Coated
Used for higher end graphics
Because 4 colour print plates are
utilizing the 4 process colours.
required, the total print plate costs tend to
It provides a stronger visual
be more expensive than Flexo Line.
impact, and enables photo

quality images to be used.
Minimum run quantities tend to be much

higher than Flexo line.
Allows the use of a solid 100%
Flood coats can be applied with stock
coverage of colour. Most
print plates, so die costs are not an
commonly used with POP
expense for the client.
displays and packaging for

retail applications.
Label Laminate
Achieved by gluing printed
It provides a clean professional
sheets to the outer surface of

the corrugated material.
appearance that looks comparable to

high end packaging similar to that used
Enables the application of a
with software and electronics. Labels can
glossy process colour (photo
be applied as a 100% coverage, or as a
quality) image, and is a
spot label in conjunction with other Flexo
reasonable cost option for low
line printing.
to medium quantity runs. Label

size is limited by the maximum
sheet size of most commercial
presses (28" x 40").
Screen Print
Another way of applying
This process is most commonly used for
graphic intensive images
POP displays and retail packaging
directly to the outer surface of
applications, and can be more cost
the corrugated package.
effective is short run quantities. Size

limitations are larger than label laminate,
and colour combinations greater than 4
are possible.
Litho Laminate
Provides a similar finished
The printed surface is actually part of the
product as label laminate, but
packaging material, as opposed to label
requires much higher minimum
laminate which is added manually.
runs (typically 10-20K).

Preprint
Providing a similar finished
It requires very high volume runs, and a
product to Flexo process, this
significant upfront investment by the
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process involves the client
client, but can be a cost effective way to
purchasing pre printed rolls of
apply impactful graphics at those
paper that are used in
quantities. Most commonly used in the
manufacturing linerboard.
food and beverage industry, like beer

cases and mandarin orange boxes.
Corrugated Board Strength

Board strength are all the factors that define how strong the box should be. There are a number of questions you must ask yourself before you can accurately asses how strong a particular box should be manufactured to be such as:
The nature of the products being packaged
The total weight of the box
The size of the box
How the cardboard box will be stacked, stored, and transported.
Boxmaster provides you with two different levels of customization options when selecting box
strength. The first is the flute type and the second is using the edge crush test.
Corrugated Flutes are the S shaped waves/arches of a corrugated box that makes up the
board. This is called the boards corrugation. Flutes are essentially the reinforcement that
make up the board. They run parallel to the depth of the container and give it its rigidity and
crushing/stacking strength. As well as providing stacking strength, flutes also provide insulation that protects products from sudden temperature changes. Generally speaking, larger
flutes like A & B profile provide greater strength and cushioning, while smaller flute profiles like
D & E provide better printability and foldability.
B flutes have 42-50 flutes per foot and are 1/8 thick. They provide the second highest arch
size.
B flutes provide good stacking strength and crushing resistance. Ideally used for canned
goods and displays.
C flutes have 39-43 flutes per foot and are 11/64 thick. They are the medium between A flute
and B flute and are very common.
C flutes provide good cushioning, stacking and printing properties. Ideally used for glass, furniture and dairy.
E flutes have 94 flutes per foot and are 1/16 thick. The board profile is super-thin which in
turn reduces box size and saves store space.
E flutes provide the greatest crush resistance and a super printing surface which make it an
excellent choice for die-cut custom boxes.
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Boxmaster provides you with the option of choosing between single and double-wall cardboard
construction.
Single Wall is the most common corrugation material - it simply consists of 1 layer of whatever flute type
you choose. Under normal circumstances, single wall construction will be sufficient as they are offered
from 23ECT to 44ECT.
Double Wall construction, also known as 'heavy duty' corrugation material is used for heavy or large
objects. A Double wall consists of 2 layers of flutes, usually 1 layer of B and 1 layer of C. They are
around 35% stronger than the regular single wall corrugation type. Boxmaster offers double wall
cardboard boxes from 44ECT to 61 ECT.
Flute Types
Flutes/Foot
Thickness
Advantages
B Flute
42 -50
1/8"
Good cushioning,
stacking & printing
C Flute
39-43
11/64"
Good stacking,
strength & crushing
resistance
E Flute
94
1/16"
Greatest crush
resistance & printing
surface
BC Flute
Double Wall
Very Thick
Can hold very large

& heavy items
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Design
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(http://boxmaster.com
/products/cardboarddisplays/)
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/products/customboxes/)
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Requirements
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/products
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/food-safe/)
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Sustainability
/sustainability/)
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Community
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Delta
(Annacis Island), B.C.
Canada V3M 5Y8
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Box Basics - Boxmaster

Food Safe (http://boxmaster.com/food-safe/)

Box Basics - Boxmaster

Die Cut Custom

rugated boxes devel-

are similar to regular

oped to exact specifi-

slotted containers ex-

cept that they have

customer requirements. Boxmaster can

only one set of flaps.

the box is open, which

boxes with FULL color,

allows it to slide over

available in all styles

an item. Ideal for: large

and custom sizes.

and heavy objects

Ideal for: unique prod-

ucts with special re-

and washing ma-

boxes, toy product

Full Over Lap

Roll End Tuck Top

The outer flaps overlap

These are simple

making it especially re-

need to be folded when

sistant to rough han-

assembled. These are

dling. All flaps are the

great for shipping nar-

same depth, and their

row items. Ideal for: vi-

depth equals the width

tamin packaging, retail

of the box. Ideal for:

heavy objects that require extra support

packaging, tea packaging.

Corrugated Box Flute Types

Box Basics - Boxmaster

Types of Printing Methods

The most basic type of printing

Allows the addition of company or

box, at a relatively low cost. Graphics

Used for higher end graphics

Because 4 colour print plates are

utilizing the 4 process colours.

required, the total print plate costs tend to

It provides a stronger visual

be more expensive than Flexo Line.

impact, and enables photo

Minimum run quantities tend to be much

Allows the use of a solid 100%

Flood coats can be applied with stock

coverage of colour. Most

print plates, so die costs are not an

commonly used with POP

expense for the client.

displays and packaging for

Achieved by gluing printed

It provides a clean professional

sheets to the outer surface of

appearance that looks comparable to