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Box Basics: History of Corrugated Boxes
Box Basics: History of Corrugated Boxes
This is the most common box style. All flaps are the same length from the score to the edge. Ideal for:
shipping small individual items such as cups and mugs, books.
Corrugated Trays
Corrugated Trays are basically trays to hold other objects. They are advantageous when product
visibility and easy handling are of prime importance. Ideal for: food and beverage industry products
such as bottled water, soft drinks, snack foods, and bulk packaged processed foods.
Half Slotted Containers
Half slotted containers are similar to regular slotted containers except that they have only one set of
flaps. The opposite side of the box is open, which allows it to slide over an item. Ideal for: large and
heavy objects such as refrigerators and washing machines.
These are custom corrugated boxes developed to exact specifications depending on customer
requirements. Boxmaster can manufacture custom boxes with FULL color, available in all styles and
custom sizes. Ideal for: unique products with special requirements such as cosmetic product boxes, toy
product boxes, gift product boxes.
The outer flaps overlap the full width of the box making it especially resistant to rough handling. All
flaps are the same depth, and their depth equals the width of the box. Ideal for: heavy objects that require
extra support such as refrigerators and washing machines.
Roll End Tuck Top
These are simple unglued boxes that need to be folded when assembled. These are great for shipping
narrow items. Ideal for: vitamin packaging, retail packaging, coffee packaging, tea packaging.
Description
Advantages
Flexo Line
The most basic type of printing on corrugated.
Allows the addition of company or package content info to the surface of the box, at a relatively low
cost. Graphics tend to be basic line art and text, utilizing between 1 and 3 colours.
Flexo Process
Used for higher end graphics utilizing the 4 process colours. It provides a stronger visual impact, and
enables photo quality images to be used.
Because 4 colour print plates are required, the total print plate costs tend to be more expensive than
Flexo Line. Minimum run quantities tend to be much higher than Flexo line.
Flood Coated
Allows the use of a solid 100% coverage of colour. Most commonly used with POP displays and
packaging for retail applications.
Flood coats can be applied with stock print plates, so die costs are not an expense for the client.
Label Laminate
Achieved by gluing printed sheets to the outer surface of the corrugated material. Enables the
application of a glossy process colour (photo quality) image, and is a reasonable cost option for low to
medium quantity runs. Label size is limited by the maximum sheet size of most commercial presses (28"
x 40").
It provides a clean professional appearance that looks comparable to high end packaging similar to that
used with software and electronics. Labels can be applied as a 100% coverage, or as a spot label in
conjunction with other Flexo line printing.
Screen Print
Another way of applying graphic intensive images directly to the outer surface of the corrugated
package.
This process is most commonly used for POP displays and retail packaging applications, and can be
more cost 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 product as label laminate, but requires much higher minimum runs (typically
10-20K).
The printed surface is actually part of the packaging material, as opposed to label laminate which is
added manually.
Preprint
Providing a similar finished product to Flexo process, this process involves the client purchasing pre
printed rolls of paper that are used in manufacturing linerboard.
It requires very high volume runs, and a significant upfront investment by the client, but can be a cost
effective way to apply impactful graphics at those quantities. Most commonly used in the food and
beverage industry, like beer cases and mandarin orange boxes.
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.
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
Types of Construction
Single
23
20
Single
26
35
Single
29
50
Single
32
65
Single
36
75
Single
42
80
Single
44
95
Double-Wall
48
100
Double-Wall
51
120
Double-Wall
61
140