HOW TO BUILD A BOX. Sizing:

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1 For questions or for a custom quote please contact a customer service representative at (909) You can also us at internetsales@inlandpaper.com. Sizing: HOW TO BUILD A BOX The dimensions of your shipping boxes should be governed by the fit around the product after all folding and sealing has been completed. Box dimensions are inside dimensions and should be given in the sequence of length, width, and depth. This gives the proper fit around your product. The dimensions of custom boxes are measured based on the opening of the box. The length is the longer measurement of the opening; the width is the smaller measurement of the opening. The side perpendicular to the opening is the depth of the box. Standard accepted manufacturing deviance on the inside measurements of a box is + or - 1/8 of an inch. The sequence of the dimensions of the cardboard shipping boxes (length, width, and depth) is very important. You will want to decide on the sequence of measurements depending on the product you are packaging and which way your product will easily fit into a box. For example: If you write your dimensions as a 24" length x 6" width x 6" depth it would be a top loading box such as in figure A. If you have a heavy awkward product that would be hard to fit in a box this might be the layout for you. If you write your dimensions as a 6" length x 6" width x 24" depth it would be an end loading box as in figure B. End loading boxes are usually cheaper than top loading boxes, because they use less material. If it would be easy to manipulate your product through a 6 x 6 opening this might be the custom size cardboard box for you. Page 1

2 Outside dimensions might be of a concern to you if you will be placing your carton within another package, or if it is a very large box to make sure you are within the shipping limitations of a carrier, or for proper palletization and distribution. Outside dimensions run significantly larger then inside dimensions. If the outside dimension is of concern to you, please notify us of the fact. For a single wall RSC box the outside dimensions will increase over the inside dimensions by 7/16" on both the length and the width; and 3/4" on the depth. For a double wall RSC box the outside dimensions will increase over the inside dimensions by 11/16" on both the length and the width; and 1-1/4" on the depth. For a single wall FOL box the outside dimensions will increase over the inside dimensions by 7/16" on both the length and the width; and 1-1/8" on the depth. For a double wall FOL box the outside dimensions will increase over the inside dimensions by 11/16" on both the length and the width; and 1-7/8" on the depth. Board Type: 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 125T to 350T and 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 Page 2

3 than the regular single wall corrugation type. We offer double wall cardboard boxes from 200T to 350T and 42 ECT to 51 ECT. Corrugated cardboard boxes are formed from two main components: the linerboard and the medium. The linerboard is a flat sheet of paper. The medium is called flutes and is constructed of a series of arches (wavy fluted paper). The flutes are a major component of the cardboard's strength. Flutes come in a variety of sizes and are designated by a letter such as A, B, C, E. As a common rule, the larger flute sizes provide greater vertical strength for outer packaging. The smallest flute sizes are used in lightweight retail packaging to increase graphic capabilities. The cardboard is formed by using a starch based adhesive to sandwich the flutes between a top and bottom layer of cardboard. Traditional corrugated cardboard boxes strength is measured by its burst strength and combined weight of its linerboards. Edge Crush Test (ECT) corrugated cardboard was introduced in 1991 as a cost savings to traditional cardboard. This cardboard uses less fiber than traditional cardboard to meet strength standards. Box strength is measured in two different ways. The mullen test measures resistance to rupture in pounds per square inch (psi). Linerboard constitutes the bulk of the bursting strength of a corrugated sheet. The basis weight of the paper as measured in lbs/1000 sq. ft. directly impacts paper strength. Burst strength is more relevant when product containment or puncture resistance is the main concern. "C" Flute corrugated has a very high stacking strength and a higher resistance to being crushed. It is one of the most commonly used flutes for shipping boxes and tends to perform the best when holding materials such as glass, furniture and food products. "B" Flute corrugated is the perfect combination of strength and style. It has a higher resistance to punctures than the other flutes and usually consumes less space than the regular "C" Flute. It is most often used for boxes that have to be durable but also need to have some style. Generally used for stand up displays or ballot boxes. Page 3

4 "E" Flute is a stronger alternative to paperboard and performs great when used for die cut designs. "E" Flute has a superior printing surface and works best when used as software packaging or point of purchase boxes. Edge Crush Test (ECT) measures the ability of combined board to sustain a top-to-bottom load. The strength is directly related to the compression strength of both the liners and medium. ECT is more relevant when stacking strength is the main concern. ECT is more relevant when stacking strength is the main concern. Designation Flutes / Lineal Foot Thickness Advantages C Flute 39 +/- 3 3/16 Good stacking, strength & crush resistance B Flute 47 +/- 3 1/8 Good cushioning, stacking & printing E Flute 90 +/- 4 1/16 Greatest crush resistance & print surface F Flute 128 +/- 4 1/4 Double Wall See Flute 5/16 Can hold very large & heavy items Triple Wall See Flute 9/16 Can hold very large & heavy items Mullen Test ECT Equivalent Maximum Dimensions Max Total Weight of Box & (L + W + D) Contents 125T 23 ECT Lbs 150T 26 ECT Lbs 175T 29 ECT Lbs 200T 32 ECT Lbs 250T 40 ECT Lbs Page 4

5 Mullen Test ECT Equivalent Maximum Dimensions Max Total Weight of Box & (L + W + D) Contents 275T 44 ECT Lbs 350T 55 ECT Lbs 200T DW 42 ECT Lbs 275T DW 48 ECT Lbs 350T DW 51 ECT Lbs All board is available in kraft, white one-side and white two-side. Most Common Box Styles: Regular Slotted Carton (RSC) 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. Where the product requires additional protection over the top or bottom, corrugated pads can be placed between the inside flaps. Auto-Bottom RSC Available with tuck-in top or with RSC-style top flaps (shown). The bottom of the box snaps into place without tape for quick assembly. Best suited for light-weight products. Page 5

6 Full-Overlap Slotted Carton (FOL) Ideal for boxes with relatively narrow widths. The outer flaps overlap the full width of the box making it especially resistant to rough handling. And, the extra thicknesses of corrugated material on the top and bottom panels provide added stacking strength. Partial Overlap Carton (POL) All flaps have the same length. The outer flaps overlap by one inch or more. The box is easily closed, usually with staples through the overlap area. This style is used when the length of the box is considerably greater than the width, resulting in a long gap between the inner flaps. The sealed over-lap helps to keep the outer flaps from pulling apart. Half-Slotted Carton (HSC) Frequently used for both shipping and shelf storage, and in applications where the cover must be removed and replaced frequently. The top of the HSC box is a tray style which usually extends less than 2/3 the depth of the bottom (PHSC), but can be made to extend the full depth of the bottom (FHSC) if extra strength is needed. Page 6

7 Telescoping HSC Can be made with either a Full telescope top (FTHS), or a Partial telescope top (PTHS). The two thicknesses of material at the sides and ends of a FTHS box provide maximum protection for the box's contents as well as giving the box superior stacking strength. And, the top is easily removed for examining the contents. Five-Panel Folder Is perfect for shipping very long products. Because the 5PF has several thicknesses of material on each end, it has a particular advantage when used for packaging long articles of small diameter which might be readily damaged if forced through the ends of the box. One-Piece Folder (OPF) Made from one piece of material and has a flat bottom with flaps that form the sides and ends. The outer flaps meet at the center to form the top. OPF's can be made with multiple scores so that one box can be folded to make up to three different size boxes. The OPF is used principally for shipping books, catalogs, videos, and similar items. OPF's are easy to store, set up, and close. Page 7

8 Die-Cut Mailers A Die-Cut Mailer is available with or without dust flaps. The box is folded up and the sides lock into place with locking tabs. This box style is generally used to package smaller products and is multi-purpose. Trays Trays have an unbroken bottom with no top and are generally not used as a shipping container on their own. Flaps on slotted trays are taped or stapled by the end user to form the sides of the container. Die cut 4-sided locking trays have self locking tabs on the side flaps for easy assembly. Trays are often used for produce items, storage, or as elements of display stands. Pads / Sheets A flat piece of corrugated with or without scores. Among its many functions, pads are often used as an added layer of protection, to separate products or layers of product, to cover pallets, or as space filler. SCORED PADS - Are used to create custom inner packing. Scored Pads can have up to nine score lines to create many different shapes for keeping products from moving inside a box. Scored Pads such as corner pieces, angles, etc. can be made to fill almost any space to firmly hold products in place during shipping. Page 8

9 Inserts / Dividers Inserts may take many shapes and are generally used for supporting, cushioning, or separating product in a master carton. This inner packaging may also be used to suspend product or to fill space. Dividers are used to create separate compartments within a larger box to protect small or delicate products. Printing: Flexography: Also known as direct print, flexo printing is the most widely used printing process. Economical for both small and large press runs, and for simple graphics and pleasing color, it is often just what you need. Advantages of Flexo Printing: It is cost effective for many applications. It enables faster turnaround time. Flexo has the ability to print a wide range of inks, including fluorescents and metallics. 1-3 Color Print. It uses resilient rubber or photopolymer image carriers that can print millions of impressions. Litho Lamination: Litho lamination combines the strength of corrugation with the appeal of high quality lithographically printed sheets or pre-printed rolls. This process results in very high quality printing and is generally used for high-end retail packaging. Advantages of Litho Lamination: Litho lamination offers the consistent high quality of offset printing, much tighter registration and better quality than flexography, and much finer screens and halftones than screen printing. Up to 6-Color Process Print Appropriate for medium-sized production runs. Page 9

10 Digital Printing: Graphics from a digital computer file are transmitted directly to a printer that plots the graphics onto the corrugated board. This eliminates the need for printing plates making short run jobs more cost effective. Digital corrugated printing is ideal for those projects requiring fast turnaround. Advantages of Digital Printing: Double-Sided Printing High resolution graphics, vibrant image Cost-effective short runs of high quality output Up to 6-Color Process Print For questions or for a custom quote please contact a customer service representative at (909) You can also us at internetsales@inlandpaper.com. Page 1 0