The Ultimate Guide to Custom Shipping Boxes

eCommerce companies know that packaging is essential. Not only must it protect the products being sent, but it should also place the brand in a positive light. Unboxing a product is part of the shopping experience, and exceptional packaging can elevate your brand above the competition.

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Custom-branded shipping boxes create an unforgettable unboxing experience for your customers. But, before you make a bulk order, you must ensure that box packaging suits your customers and products. While it has its place, there are times when mailers or other forms of packaging might make more sense. On top of this, not all shipping boxes are the same. Once you decide that custom boxes are the way to go, you must determine which boxes are best for your brand.

That&#;s why we&#;ve put together this handy guide covering everything you need to know about custom shipping boxes before you buy. Let&#;s dive in!

Table of Contents:

What is a shipping box?

A shipping box&#;also referred to as a packing box or a mailer box&#;is characterized by its corrugated walls. The slight padding makes it a robust packaging choice, ideal for fragile items or those that require something more rigid than a poly mailer or other more flexible packaging choices. Depending on how they are secured, there are a few different shipping boxes to choose from. We will talk more about that below.

What&#;s the difference between a box and a carton?

The critical difference between boxes and cartons is their thickness. Boxes are typically corrugated and rigid, suitable for stacking and long-term storage. Conversely, cartons are thinner&#;think cereal boxes or milk cartons&#;and less durable but more lightweight. It&#;s usually best to choose a shipping box or a mailer over a carton for shipping, as cartons may not fully protect your products during transit.

Why choose box packaging?

Because of their rigidity and durability, mailing boxes are ideal for shipping items that need protection. Almost all products can be shipped in a corrugated box&#;apparel, appliances, jewelry, skincare, yarn, food, etc. The question isn&#;t what can be shipped, but what should you ship in a box.

The pros of shipping in a box:

• They do a great job protecting your products.
• They make for a sleek presentation.
• They come in virtually infinite dimensions, so you can likely find one to meet your needs.
• Once filled, shipping boxes are stackable, making them ideal for warehouse storage.
• They are made with paper, a renewable resource, and can comprise up to 100% recycled content.
• They are recyclable and compostable.

The cons of shipping in a box:

• They are not 100% weatherproof.
• They are typically more expensive than mailers.
• They are heavier than mailers. This can result in higher shipping costs on both inbound boxes and outbound boxes.
• They take up more space in your warehouse.
• They must be assembled and taped, requiring more labor than a mailer.
• They use more material than a mailer.

Which products are best suited for a shipping box?

Some items ship better in a box. They may be too heavy for a poly or paper mailer or too fragile for more flexible packaging choices. Here&#;s a list of product types that should be shipped in a box.

Large or bulky items

These include boots, water bottles, blenders, or children&#;s toys. Items that are wide, tall, and relatively deep often need a box rather than a mailer. Often, these items carry some weight and might break through a paper or poly mailer. Additionally, bulky items in a mailer are difficult to stack in a truck or store in a warehouse. It&#;s easier for the shipper to pack these items in a stackable mailing box.

Collections of items

If you&#;re shipping a few items in a single order, a box works better than a mailer. If your business sells smaller products&#;like face cream or jewelry&#;you can have one or two shipping box sizes on hand that work for almost all orders.

Fragile items

Items that must be handled carefully, such as large glass bottles or candles, need a sturdy shipping box. While small, compact bottles can often be wrapped and shipped in padded mailers or bubble mailers, a shipping box is the best option for larger glass bottles. Boxes also tend to better protect items with sharp corners, like hardcover books and picture frames, than mailers.

Items that demand high-end presentation

A custom shipping box provides an impressive experience for customers. Boxes retain their shape and allow items to be arranged appealingly with customized elements like tissue paper. For this reason, some companies selling products that could be sold in a mailer (such as apparel) will still opt for a box.

Items shipped as part of a subscription service

Subscription services or &#;box of the month&#; companies typically use boxes for the above reasons. Successful subscription services understand the importance of creating an appealing unboxing experience that keeps customers returning.

Learn more on our blog: Choosing Between a Mailer or a Shipping Box

What type of shipping box should I use?

When it comes to custom shipping boxes, there are five basic styles to choose from. Here&#;s what each is best suited for.

Tab locking (TL)

These are the boxes we recommend the most and sell the most. Many brand-conscious eCommerce businesses use their classic presentation style to create a fantastic unboxing experience for their customers. Logos and branding look great on the box lid, while the locking tabs create a clean seal. They&#;re also ideal for most eCommerce products, including apparel, accessories, cosmetics, small toys, and outdoor wear. However, you should avoid the TL when shipping large boxes (greater than 15&#; x 15&#;) or heavy goods (> 15 lbs).

Literature mailer (LM)

Very similar in design to the TL box, this box style can be used for the same items, and it even shares a similar material footprint, which is why we price them the same. For most customers, the choice between the two comes down to aesthetics. The literature mailer&#;s seam is on the top edge of the box, whereas the tab locking box has it on the bottom edge. Furthermore, The LM&#;s lid rests on the sides of the box, which hides the side seams and folds that you can see on a TL. The LM is also quicker to assemble due to the lid folding into the box versus the TL&#;s two tabs that fold into slots.

Regular slotted container (RSC)

As the traditional industrial box, RSCs are probably what you think of when you picture shipping boxes. Each side has a tab that folds over, and the seam is taped shut on the top and bottom. RSCs are great for heavy products (> 15 lbs) and those that require deep box sizes (> 6&#;). Many customers use RSCs when packing fragile items in packaging paper or heavy items such as books, liquids, or ceramics.

Five-panel folder (FPF)

The five-panel folder is very similar in design to the RSC, except FPFs have an extra inside flap that reinforces the box's structural integrity. This design is best for tall or long items such as a wooden sculpted Statue of Liberty, a skyscraper model, or a baseball bat.

One panel fold (OPF)

In a class all by itself, the OPF is an excellent box for slim, flat items such as picture frames, prints, and books. These are sometimes referred to as mailer boxes because they are thin and have some of the characteristics of a flat envelope mailer, even though they are constructed from corrugated materials. The OPF flaps fold around the product and meet on the backside, creating a clean front panel with no seams that look great when printed. We have several variations depending on how quickly you need to pack your items. For example, we have developed a wrap-around OPF that allows you to wrap the product instead of folding it over each of the four sides. The OPF is a great way to package large volumes of the right product in record time.

Corrugated pads

While corrugated pads are not a custom shipping box type, they are a custom-sized corrugated product that serves as a shipping accessory, so we&#;re including a description here.

These typically serve one of three purposes:

• Product divider: Imagine two similarly sized wooden jewelry boxes sitting side by side in your shipping box. You&#;re concerned they will knock against each other, chipping paint or damaging the wood. Place a corrugated pad between the jewelry boxes to keep them from bouncing into each other during transit.

• Additional compression protection: A semi-fragile bottle of lotion or oil could benefit from a layer of compression protection. Adding a pad to the package's top and/or bottom gives you more cushioning upon impact.

• Increase the rigidity of a print: Used frequently by artists when shipping with mailers, a corrugated pad adds rigidity to your print to reduce the chance of bending during transit.

Scored pad dividers can separate two or more products within your box, providing more visibility and protection to each piece. Imagine shipping a t-shirt and a rolled print in a single box. Without a divider, the t-shirt will move around, damaging the print. With a divider, the t-shirt can arrive looking sharp and folded, and your print will remain intact.

Trays

Trays are not technically boxes like pads, but they play a critical role in shipping. They&#;re often used to transport plants, cans, bottles, and other items within a retail or warehouse environment. Trays are similar to Tab Locking Boxes and Literature Mailers, just missing the top closure.

Choosing the correct shipping box for your products comes down to the types of products you&#;re shipping and the aesthetic and unboxing experience you&#;re seeking. Need help to figure out the best shipping box for your eCommerce company? Try out some free samples, or contact us for more guidance.

What are flutes?

A corrugated sheet has linerboard (the flat outer covering) and flutes (the s-shaped, wavy paper between the linerboard). The flute enables corrugated sheets to resist bending and allows the sheets and boxes made from them to withstand pressure.

Flutes vary in two main characteristics: their height (which creates the thickness of the cardboard sheet) and how tightly or loosely they&#;re waved.

What does shipping box strength mean?

Three factors determine the strength of a specific box:

• The style
• The dimensions
• The strength rating of the corrugated sheets

This strength rating of the corrugated sheets depends on:

• Flutes
• Weight
• The thickness of the linerboard
• The material used for the linerboard
• The adhesive used to glue the flutes to the linerboard

Shipping box strength is noted with a number and a letter&#;the number refers to how much weight a single sheet can withstand when standing on its edge, while the letter refers to the tightness of the corrugate waves. The higher the number and the letter, the stronger the box is.

Learn more on our blog: Understanding Shipping Box Strength

What size shipping box do I need?

At EcoEnclose, every single box we sell is custom cut, so it&#;s the exact size you need it to be. Minimize the extra, unnecessary air within your custom shipping box for more eco-friendly, less expensive, and visually appealing shipping.

Are you trying to determine the right size for your custom shipping box? We recommend laying out your items to ship on a table and measuring an imaginary boundary around your products to determine the length, width, and height of your shipping box.

Note that the dimensions you input on our site for boxes refer to the inside dimensions of the box you will receive. If you have any doubts, we recommend ordering a free sample before stocking up to ensure your box is the perfect size.

Learn more on our blog: Right-Size Your Sustainable Packaging

Can my custom shipping boxes also be custom-branded?

Yes! Branding your boxes can be a great way to promote your brand and wow your customers. There are several printing options available to eCommerce companies and retailers. Here are the three most common box printing styles.

Flexographic printing

With this type of printing, we&#;ll turn your design into a &#;plate,&#; which is then used to stamp your boxes with fast-drying ink. We charge a setup fee, and it will take a little time to create your plate, but then the per-box printing fee is relatively low. Furthermore, we will keep your plate for all future orders once your plate has been created. As a bonus, flexo printing (unlike digital printing) allows for using soy- and water-based inks, which are non-toxic and safely recycled or composted.

Screen printing

This is a process by which ink is forced onto a surface through a prepared screen of fine material to create the desired design. Because the ink is applied thickly, it creates vibrant designs, perfect for colorful branding and logos. It&#;s typically used on apparel but can print on corrugated cardboard.

Digital printing

Digital prints allow for an immense array of colors and designs in matte or gloss finish, and the setup time is pretty low. However, the cost per box is relatively high, so digital corrugated printing isn&#;t typically used for high-volume shipper boxes but instead on displays or retail packaging.

At EcoEclose, we opt for flexographic printing for its gorgeous aesthetic and friendliness to the planet. We offer single-color custom printing on virtually any box size and style for just 100 units. For further customization, we also have multi-panel printing options, and we can print on the inside or outside of each box in one or two colors. This means you can get the environmental benefits of flexographic printing on 100% recycled kraft boxes, and you&#;ll still get a gorgeous, well-designed box that conveys your brand identity.

Even better, when you work with EcoEnclose, you can print your boxes with Algae Ink&#;&#;a unique carbon sequestering black ink made with algae cells.

Learn more: EcoEnclose&#;s custom printing services for boxes

Are custom shipping boxes eco-friendly compared to poly mailers?

There are many things to consider regarding your shipping containers' entire environmental life cycle. When comparing a plastic mailer to a paper shipping box, it first seems obvious&#;paper is better for the environment than plastic, right? Unfortunately, it&#;s not that simple.

Shipping boxes carry a higher footprint during production

Typically, a cardboard box requires more resources and energy than an equivalent plastic mailer.

One 13&#; x 19&#; x 2&#; cardboard box requires 0.7 lbs of paper, while one 12.5&#; x 18.25&#; x.25&#; poly mailer requires 0.052 lbs of plastic. The same box takes 23 times more energy and emits six times more CO2 in production than the mailer. So, even though paper comes from a renewable resource while plastic derives from nonrenewable fossil fuels, the production of corrugated boxes carries a higher environmental footprint than plastic.

Cardboard carries a higher carbon footprint associated with shipping

The carbon footprint of shipping is driven both by the dimensions and weight of packages. Cardboard is typically heavier than an equivalent poly mailer and requires more energy to ship.

Boxes have a cleaner end-of-life

Most boxes and poly mailers can be reused at least once. However, most of them are not reused. Consumers are far more likely to recycle cardboard boxes than plastic mailers. According to a American Forest & Paper Association study, 93% of cardboard boxes were recycled. This shows that although poly mailers have some eco advantages in manufacturing and logistics, most are still landfill-bound. Conversely, boxes are more likely to be recycled and returned to the industrial supply chain.

Bottom line: Make the best decision you can

Paper has its advantages, just like plastic mailers. Ultimately, we recommend you make the best decision for your products and company. What protects and presents your goods as effectively as possible? If you have decided that boxes are the best solution for you, then the best thing you can do for the planet is to work hard to make all aspects of your shipper boxes sustainable.

The good news is that EcoEnclose makes it easy to make sustainable choices. Most of our packaging options are made from 100% recycled materials and are recyclable, ensuring as little impact on the planet as possible. No matter which option you choose, it will be a good one.

Learn more on our blog: How to Choose Between a Mailer and a Shipping Box

How do you develop a truly sustainable custom shipping box?

Many companies use a shipping box and, because the box is curbside recyclable, showcase it as a sustainable option. This is incredibly misleading; a box made with virgin content is a major environmental miss. Brands that genuinely want to do right by the planet need to choose packaging that goes above and beyond when it comes to the planet. Here are the key things sustainability-minded businesses should look for in their packaging.

Choose as much recycled content as possible

Many companies tout &#;made with recycled content&#; on their boxes. This is a fuzzy statement that, as a standard, typically means that it&#;s made with approximately 30% recycled content. This isn&#;t enough.

Look for boxes with 100% recycled content and as much post-consumer waste as possible. Our boxes are 100% recycled, with at least 95% post-consumer waste. Acknowledging that paper products made with recycled content are weaker than their virgin counterparts is essential. Virgin paper fibers are longer, and longer fibers interweave better, leading to stronger paper.

In some situations, 100% recycled corrugated isn&#;t strong enough. But we&#;ve found that most products shipped to customers work well in our 100% recycled boxes. We encourage you to order a sample or contact us if you have concerns about the quality and strength of recycled cardboard.

Make your box as small and snug as possible for your needs

If you order stock sizes from a supplier, work hard to find the most suitable size for your needs, or, better yet, order custom sizes so you know you are using only what you need. Boxes that are too big for their products require more materials and protective filling and often weigh more, contributing to your environmental footprint. Opting for a snug fit mitigates those issues.

We are committed to reducing waste. That&#;s why EcoEnclose&#;s 100% Recycled Shipping Boxes are available in many configurations, and every box is customized to your specific needs so your unique products fit perfectly.

Encourage your customers to reuse, recycle, or compost their boxes

Companies are in a unique position to encourage behavior change. Use your brand to encourage your customers to make more environmental choices. Let them know how to properly dispose of or reuse your packaging in your confirmation or shipping emails. Add a stamp or a note in their box encouraging them to dispose of their shipping boxes responsibly. Or take a cue from some of our super creative companies and provide cool ideas for reuse. For example, one company filled their box with seed paper and encouraged customers to plant a garden in the box itself.

Choose eco-friendly shipping services

A significant portion of any eCommerce company&#;s carbon footprint comes from shipping. Minimize your footprint by choosing eco-friendly shipping options. If you do not need your boxes immediately, select ground shipping and encourage your customers to do the same.

Shop custom shipping boxes

Ordering custom shipping boxes is simple. Select your style, dimensions, strength, and branding - we'll handle the rest. For branded orders, we have a real, live human proof your artwork prior to production to ensure your vision is captured into a beautifully finished product.

Get started: order custom shipping boxes here

Learn more about shipping boxes

How to Choose the Right Flute Type in Corrugated Boxes

Selecting the right cardboard box for packaging involves considering several critical factors to ensure your product is well-protected during storage and shipping. Boxes serve a vital role, not only in protecting products but also in building a company's brand identity and delivering a memorable unboxing experience for customers. Cardboard boxes are also selected based on its sustainability and shipping requirements.

These considerations encompass:

Box Type: Selecting the right type of cardboard box is a crucial decision in the realm of packaging. There are two primary options to consider: paperboard boxes, often referred to as product boxes, and corrugated cardboard boxes, known for their strength and durability.

Paperboard Boxes (Product Boxes): Paperboard boxes are known for their slim profile, typically measuring 0.010 inches or less in thickness. Paperboard thickness is typically measured in either grams per square meter (GSM) or points. The thinnest white paper falls within the range of 35-55 GSM, commonly found in newspapers and magazines. Standard office paper falls between 90-120 GSM and is widely used for various purposes. Promotional posters often use paper weighing 130-250 GSM. For high-quality brochures and magazines, heavier yet flexible cards ranging from 260-300 GSM are suitable. The thickest and sturdiest paper, with a weight of 350-450 GSM, is ideal for making product boxes, business cards and invitations.Despite their thin appearance, they offer remarkable flexibility, sturdiness, and an elegant look. These qualities make them a popular choice in industries where aesthetics and durability are paramount, such as cosmetics, bakery goods, toiletries, and clothing.

Ensuring the durability of the chosen paperboard box is vital to withstand the rigors of shipping. As products traverse from manufacturer to consumer, they encounter diverse challenges, including mechanical stress, temperature variations, and environmental factors. Consequently, safeguarding products from potential damage during transit becomes paramount. The durability of a paperboard box functions as a protective barrier for the enclosed items, shielding them from external forces like handling impacts, transportation vehicle vibrations, and harsh weather conditions. Boxes lacking in durability pose a risk to the products they contain, potentially resulting in breakage or spoilage during the shipping process.

Corrugated Cardboard Boxes (Shipping and Mailer Boxes): Corrugated cardboard boxes are known for their thickness and strength. These robust boxes are versatile and find applications in various scenarios, from mailers and pizza boxes to shipping, moving, and storage containers. They excel in withstanding the rigors of transit and providing superior protection to their contents.

The choice between paperboard and corrugated cardboard hinges on the specific needs of your product and the level of protection required. Paperboard boxes shine in presenting products elegantly, while corrugated cardboard boxes prioritize strength and durability, making them ideal for shipping and protecting items in transit.

Types of Corrugated Cardboard in Box Manufacturing: Corrugated cardboard consists of flat liners with wavy layers known as flutes sandwiched in between.

These flutes come in various types (A, B, C, E, F, D, N, G and T), each suited for different product needs. Smaller flutes generally offer enhanced crush resistance and printability, while larger flutes provide better cushioning and stacking strength. The choice between them depends on specific packaging needs and the desired level of protection for the enclosed products. The number of flutes per square foot has a significant impact on cardboard strength. 

Flute Type

Flute Height/ Thick-ness

Inches

Flute Height/ Thick-ness

Milli-meter

Flutes Per Linear Foot

Common Uses

A Flute

1/4&#; or 0.25 inches

5 mm

33

Thickest and strongest, compression resistance, cushioning properties (storage boxes, fragile items packaging)

B Flute

1/8&#; or 0.125

inches

3mm

49

Padding, displays, inner packaging, can be printed (mailer boxes, retail packaging and cardboard sheets)

C Flute

11/64&#; or 0.17

inches

4mm

39

Heavier items, can be printed (shipping boxes, furniture packaging, glass packaging, Dairy packaging)

E Flute

1/16&#; or 0.06

inches

1.5mm

90

Retail packaging, less strong, can be printed (mailer boxes, displays, ballot boxes, pizza boxes)

F Flute

1/32&#; or 0.031

inches

1mm

125

Thinnest and flexible, sleek appearance (jewelry boxes, displays, shoe boxes, cosmetic packaging)

D Flute

11/50&#; or 0.22

inches

2mm

72

Thicker and stiffer (take out boxes, pizza boxes, food packaging and pallets)

N Flute

1/50&#; or 0.02

inches

0.5mm

170

Thin, lightweight, smooth (cosmetic, jewelry packaging, printing)

G Flute

1/32&#; or 0.031

inches

0.8mm

90

Thin and lightweight (pizza boxes, cake boxes, cereal boxes)

T Flute

3/64&#; or 0.046

inches

1.2mm

116

Thin, smooth, flexible (retail displays,bakery boxes, mailers used to pack dvd,cd, books)

R Flute

3/32&#; or 0.090 inches

2.3mm

61

Thin, strong, smooth, better print surface, crisper creasing (mailer boxes, retail packaging, cardboard sheets)

Product Weight: Consider the weight of your product when choosing the type of cardboard. This will influence whether you need a single-wall, double-wall, or even a triple-wall box to provide the necessary strength and durability for safe transport and handling. The weight capacity of a single wall, double wall, triple wall  box is determined by its Edge Crush Test (ECT) rating and The Mullen Test. Edge Crush Test is the testing of a cardboard flute in vertical position, which determines the stacking strength of the box. The Mullen test is testing how strong the box is to resist puncture.The Mullen Test rating is measured as pounds per square inch (psi).  Nowadays, most of the companies use Edge Crush Test in the selection of the  boxes. A box made with 200# The Mullen Test is stronger than a box made with 32 ECT. 

Single Wall Boxes: Single-wall boxes feature one corrugated medium sheet sandwiched between two liner sheets. Basically Single wall boxes are made of 3-ply corrugated sheets. Single wall boxes are made of flutes A, B, C and E.These boxes are particularly popular among Small and Medium Businesses (SMBs) and find extensive use for shipping a range of items, including jewelry, beauty products, clothing, and small goods. Estimations of weight capacity for single-wall boxes rely on their ECT (Edge Crush Test) ratings and Mullen Tests, which assess strength and durability, ensuring their appropriateness for specific applications. Given the prevalent use of single-wall boxes by SMBs, comprehending their weight-bearing capabilities through rigorous testing is essential for streamlining packaging and shipping operations.

Double Wall Boxes: Double wall boxes consist of two corrugated sheets securely glued together, forming 5-ply corrugated sheets. These boxes find extensive use in the retail sector for the storage and stacking of items like vegetables, fruits, furniture, beverages, and pharmaceuticals. They are also utilized for moving purposes. Gaylord boxes, constructed from double-wall cardboard sheets, serve similar functions. Typically, double wall boxes are crafted using a combination of BC flutes, representing one layer of B flute and one layer of C flute. This combination offers an optimal balance of strength and cushioning. Various types of double-wall boxes, including BC, EB, BB, EC, BE, AC, AB and CC, are produced using specific cardboard flute variations. The strength of these double-wall boxes is dictated by the specific combination of cardboard flute types chosen in their production process.

Triple Wall Boxes: Triple-wall boxes are constructed from three corrugated sheets, typically employing 7-ply corrugated sheets. These boxes are primarily designed for heavy appliances, substantial furniture, and large, weighty components. Gaylord boxes, commonly used for palletization and stacking, are often crafted from triple-wall sheets. The most frequently used triple-wall combination comprises cardboard with BAC, AAC, and CAC flutes.The strength of these triple-wall boxes is influenced by the specific combination of cardboard flute types selected during the manufacturing process.

Here is the table that can help to choose the right  box for the  product by weight-bearing capacity:

 

TYPE OF WALL BOX

POSSIBLE 

FLUTE TYPES

XRPINK are exported all over the world and different industries with quality first. Our belief is to provide our customers with more and better high value-added products. Let's create a better future together.

ECT RATING 

(EDGE CRUSH TEST)

MULLEN TEST (BURST TEST) 

MAXIMUM WEIGHT CAPACITY

SINGLE WALL BOX

B, C

ECT 23

125 psi

15/20 pounds

SINGLE WALL BOX

B, C

ECT 26

150 psi

25/35 pounds

SINGLE WALL BOX

B, C

ECT 29

175 psi

45/50 pounds

SINGLE WALL BOX

B, C, A, E

ECT 32

200 psi

55/65  pounds

SINGLE WALL BOX

B, C, A

ECT 40

225 psi

75/80 pounds

SINGLE WALL BOX

B, C, A

ECT 44

300 psi

85/90 pounds

SINGLE WALL BOX

B, C, A

ECT 55

326 psi

115/120 pounds

DOUBLE WALL BOX

BC, AC

ECT 44-48

275 psi

95/100 pounds

DOUBLE WALL BOX

BC, AC

ECT 51-55

350 psi

115/120 pounds

DOUBLE WALL BOX

BC, AC

ECT 61-65

400 psi

135/140 pounds

DOUBLE WALL BOX

BC, AC

ECT 71-75

500 psi

155/160 pounds

DOUBLE WALL BOX

BC, AC

ECT 82

660 psi

180/185 pounds

TRIPLE WALL BOX

BAC, AAC

ECT 67

700 psi

230/240 pounds

TRIPLE WALL BOX

BAC, AAC

ECT 80

900 psi

250/260 pounds

TRIPLE WALL BOX

BAC, AAC, CAC

ECT 90

psi

270/280 pounds

TRIPLE WALL BOX

BAC, AAC, CAC

ECT 112

psi

290/300 pounds

 

Gaylord boxes are constructed using various combinations of cardboard flutes, including double wall, triple wall, four wall, five wall, and seven wall configurations.

Dimensions of the Product: The dimensions and configuration of your product are pivotal factors in determining the appropriate box size and style. The box should be well-matched to your product's size and shape to avoid wasted space and ensure a snug fit. Precisely measure the length, width, and height of your product; these measurements are fundamental in selecting a box. In the United States, standard box measurements are typically expressed in inches, reflecting the country's predominant use of the Imperial system of measurement. These standardized box dimensions play a crucial role in various industries, from packaging and shipping to storage and retail. The common box sizes help streamline logistics, as they are compatible with pallets, shelving units, and transportation containers. This consistency in sizing not only enhances efficiency but also facilitates uniformity in pricing and labeling. It simplifies the process of selecting the right packaging solution for businesses, ensuring compatibility with industry standards and regulations while accommodating diverse product sizes and shapes.

Usage of the Box: When selecting a box, it's essential to factor in its intended purpose, as this can greatly vary and impact your choice. Boxes serve various functions, including storage, shipping, moving, or display. Each purpose demands specific characteristics from the box. Storage boxes require durability and stacking ability to efficiently organize items. Shipping boxes need to withstand the rigors of transportation and protect their contents. Boxes for moving should be easy to handle and stack securely. Display boxes prioritize aesthetics and presentation to showcase products attractively. The choice of the box type also takes into account whether the products require additional inserts to protect them during transit. These inserts can come in various forms, including foam, paperboard, anti-slip cardboards, corrugated cardboards, plastic inserts, promotional materials, or other essential information. By understanding the distinct requirements associated with these purposes, you can make an informed decision when choosing the most suitable box for your needs, ensuring optimal functionality.

Branding and Printing: When it comes to customization, printing, and branding, it's essential to choose an appropriate surface. One of the primary considerations in this regard is the brand's logo and the size of the print. The packaging itself can be seen as a canvas for incorporating a company's logo and other branding elements. The dimensions and positioning of these visual elements play a pivotal role in effectively conveying the brand's message. A well-designed package with a prominently featured logo can significantly strengthen brand recognition and recall, thereby reinforcing the company's image in the customer's mind.

When businesses embark on the journey of selecting the perfect packaging for their products, they must carefully consider numerous factors, all of which are intricately tied to their ultimate objective: creating a memorable impression and cultivating brand loyalty. Among these considerations, the brand's logo and print size take center stage. The packaging serves as a platform for showcasing a company's logo and other branding elements. The size and placement of these visual cues are vital for conveying the brand's message effectively. A thoughtfully designed box with a prominently displayed logo can serve to bolster brand recognition and recall, thus solidifying the company's image in the customer's consciousness.

In essence, companies need to align their packaging choices with their overarching goals. Are they aiming to communicate notions of luxury and sophistication, environmental responsibility, or a sense of excitement and enjoyment? By gaining a deep understanding of their target audience and the emotions they aim to evoke, businesses can select the perfect packaging that resonates with their customers and reinforces their brand identity. Ultimately, the right choice of packaging becomes a potent tool for conveying the company's values and making a lasting impact on the customer's perception.

Boxes frequently function as conveyors of essential product details, which are occasionally imprinted directly onto the packaging. This information encompasses product specifications, usage guidelines, safety advisories, and even promotional content. Moreover, packaging may incorporate handling instructions, offering guidance to those involved in shipping, handling, and receiving the package, thereby safeguarding the product's well-being and preserving its condition throughout its voyage. These printed particulars not only offer valuable insights to consumers but also play a pivotal role in upholding the product's excellence and securing its dependable delivery.

Closure Method of the Box: When it comes to selecting the closure method for your packaging, it's important to consider your specific requirements and the nature of your products. There are several closure options available, including tape, glue, and interlocking flaps, and each has its advantages and best-use scenarios.

Tape Closure: Using tape for sealing your boxes is one of the most common and versatile methods. It's easy to apply and provides a secure seal. You can choose from various types of tapes, such as standard packing tape, reinforced gummed tape, or even custom-printed tape with your logo. This method is efficient and works well for a wide range of products.

Glue Closure: Glue provides a more permanent and tamper-evident seal. It's an excellent choice for products that require extra security or for boxes that will be subjected to rough handling during shipping. Glue closures are often used for high-end packaging, luxury products, or when you want to convey a sense of craftsmanship.

Interlocking Flaps: Interlocking flaps, sometimes referred to as tuck flaps or tab-lock closures, are ideal for packaging that will be opened and closed multiple times. They offer a convenient and resealable option. These closures work well for items like folders, portfolios, or presentation boxes. They are easy to open and close without the need for additional materials like tape or glue.

To make an informed decision, consider the following factors:

Product Nature:Consider the fragility and characteristics of your products; if they demand added protection, opting for a more secure closure method like glue may be appropriate. For items that are less delicate, tape or interlocking flaps may suffice. In certain cases, products require additional safeguarding within the box, and this is where various types of corrugated sheets come into play as inserts during transit. Corrugated sheets encompass several varieties, including single face boards, single wall boards, double wall boards, and triple wall boards. Single face boards, characterized by a single fluting layer and a smooth liner on one side, are frequently utilized as inserts within boxes. Their primary role is to create separation and ensure the protection of enclosed products, thus enhancing the packaging's safety standards. Meanwhile, single wall sheets, double wall sheets, and triple wall sheets are selected based on product weight, with heavier items often requiring their use as inserts.

Customer Experience: Consider the unboxing experience and the impression you want to leave on your customers. A well-designed closure method can enhance the overall perception of your brand.

 

Efficiency: Evaluate the efficiency of your packaging process. Some closure methods are quicker and more convenient than others. Choose one that aligns with your production speed and requirements.

Tamper Resistance: If tamper resistance is crucial for your products (e.g., pharmaceuticals or sensitive documents), then glue or tamper-evident tape may be necessary.

Finally, factor in the cost of materials and labor associated with each closure method. Some methods may be more cost-effective than others, depending on your volume and budget.

Unboxing Experience: Elevating the unboxing experience for your customers involves a thoughtful blend of elements that go beyond the product itself. Start with the box color, a powerful tool for reinforcing brand identity and setting the tone for the unboxing adventure. The color you choose should resonate with your brand's personality, creating an immediate visual connection. But why stop there? Infuse excitement by incorporating playful packaging elements like tissue paper, adding a touch of elegance and anticipation. Crinkle paper can amplify the joy, enhancing the tactile experience and offering a delightful surprise. Don't underestimate the impact of combining multiple items in one box, increasing customer excitement while providing an efficient and cost-effective shipping solution. Today, the unboxing experience is more than just a transaction; it's an essential part of customer satisfaction and engagement. Craft it with care, transforming an ordinary purchase into a cherished memory. The design, color, and materials used in your packaging, along with thoughtful elements like personalized notes, can create an emotional connection. Remember, customers are not merely buying a product, they're investing in a unique, unforgettable experience.

Environmental Effects on Products: When selecting the appropriate packaging, it's essential to consider the potential environmental effects on both the box and the product during transit. This consideration becomes particularly critical for industries dealing with sensitive items like food and medical products. Environmental factors such as temperature fluctuations, humidity, and exposure to contaminants can significantly impact the integrity and safety of these products. Choosing packaging materials and designs that offer adequate protection against these environmental variables is essential to ensure product quality and safety. By addressing these concerns proactively, businesses in the food and medical sectors can maintain the highest standards of product preservation and consumer well-being.

Regulations and Compliance : When making your packaging selection, it's vital to take into account the specific packaging standards and regulations within your industry. Ensure that the cardboard box you choose aligns with these industry-specific requirements, as they can vary significantly depending on your sector. Compliance with these standards not only guarantees the safe and lawful packaging of your products but also reflects your commitment to professionalism and quality. By staying informed and adhering to these regulations, you demonstrate your dedication to meeting the unique demands of your industry, enhancing product safety, and maintaining a strong reputation within your niche. It's a crucial aspect of responsible and effective packaging decision-making.

Shipping Cost of the Box: When considering the shipping cost of your package, optimizing space by efficiently packing multiple items together can significantly reduce shipping expenses. It's vital to evaluate the fragility or durability of your products, as this directly influences your packaging requirements. Additionally, take into account the dimensions and weight of the box, as these factors play a crucial role in determining the overall shipping cost. Strive to select packaging materials that strike a balance between durability and affordability.

To calculate the shipping cost of a package, various factors come into play:

• Shipping Destination:

  The shipping destination is a fundamental factor. Whether you're shipping domestically within the US or internationally, it significantly impacts the cost. For domestic shipments within the US, there are typically eight zones, and the shipping cost increases with the distance from the point of origin.

• Delivery Timeframe: The desired delivery time frame selected by the customer is another pivotal consideration. Shipping companies offer diverse delivery options, including:

• Same Day Delivery: The quickest service for same-day arrival.

• Next Day Select: Ideal for overnight shipments requiring swift delivery.

• 2nd Day Select: Packages reach their destination within two days.

• 3-Day Select: Suitable for less time-sensitive express shipments.

• Ground: Day-definite delivery, taking between 5 to 8 days. Note that some companies operate exclusively on business days, while others provide weekend delivery. Certain carriers also offer the option to hold packages for specified durations upon request.

• Dimensional Weight (DIM):

  DIM weight, often referred to as DIM, determines the billable weight of the package. To calculate DIM, follow these steps:

• Measure the length, width, and height of the box, with the length being the longest side.

• Determine the actual weight of the box.

• Use the formula DIM = (Length x Width x Height) / DIM factor, where L represents length, W is for width, H is for height, and DIM is the dimensional weight.

• Different shipping carriers like UPS, USPS, FedEx, and DHL have their specific DIM factors.

• Round all measurements to the nearest whole number.

Each major shipping carrier employs specific DIM(Dimensional) formulas to determine shipping costs based on package size. Here are the formulas used by these carriers:

UPS:

• For Daily Rates: DIM weight = (Length * Width * Height) / 139

• For Retail Rates: DIM weight = (Length * Width * Height) / 166

• For countries using centimeters: DIM weight = (Length * Width * Height) /

• The billable weight is the greater of the dimensional weight or the actual weight.

• Additional handling charges may be incurred for packages with dimensions where the longest side of the box exceeds 48 inches or the second-longest side of the box exceeds 30 inches.

•  If the average weight of the box is greater than 50 pounds or packages over 50 pounds additional handling charges are added by UPS.

USPS:

• DIM weight = (Length * Width * Height) / 166

• USPS applies dimensional weight for packages larger than one cubic foot. The maximum actual weight allowed is 70 pounds.

• USPS stands out as the most cost-effective choice for shipping packages weighing less than 2 pounds, making it the overall economical option for domestic shipments in the United States.

FedEx:

• Using inches per pound: DIM weight = (Length * Width * Height) / 139

• Using centimeters per kilogram: DIM weight = (Length * Width * Height) /

• Make sure to check size and weight restrictions.

DHL:

• DHL calculates cost based on volumetric weight, considering both actual and volumetric weight. The formula varies by transportation mode:

• For air freight: ((L x W x H, in centimeters) / 6,000) x number of packages

• For ocean freight: ((L x W x H, in centimeters) / 1,000) x number of packages

• For rail freight: ((L x W x H, in centimeters) / 3,000) x number of packages

• Density ratios may vary by location and carrier for road freight.

Keep in mind that each carrier may have its own terms, size restrictions, and weight limits, so it's essential to check their specific guidelines before choosing a shipping option.

Billable weight of the Box: Billable weight is a method employed by carriers to determine shipping costs per package, considering both the dimensional weight (dimensions like length, width, and height) and the actual weight of the shipment. The higher of these two weights is used as the billable weight for your shipment, which in turn dictates the applicable shipping rate.

Additional Surcharges: Certain shipping companies may apply extra charges to shipments based on various factors.

• Residential surcharges

• Deliveries to rural or remote areas

• Address inaccuracies

• Oversized packages

• Incorrect weight or dimensions provided for the box

• Adherence to packaging regulations such as using strapping or tape for sealing

• Peak-season surcharges

• Incorrect placement of the shipping label (if not on the longest side of the box)

• Box dimensions and shapes

• Overweight packages

• Delivery time selection

All of these elements collectively impact the overall shipping cost of a package. Businesses and customers should carefully consider these factors when planning their shipments.

Sustainability of the Box: Prioritizing environmental sustainability within your business entails opting for easily recyclable cardboard boxes. Embracing eco-friendly or recyclable packaging aligns with your company's sustainability objectives and resonates with environmentally-conscious customers. By choosing cardboard boxes that can be readily recycled, you contribute to reducing environmental impact and waste. This commitment not only demonstrates your environmental responsibility but also appeals to a growing market of eco-conscious consumers who actively seek products packaged in environmentally-friendly materials. It's a proactive step toward building a positive brand image, fostering customer loyalty, and ensuring your business aligns with the values of sustainability and responsible resource management.

In summary, taking into account factors like product fragility, dimensions, weight, shipping destination, and suitable packaging materials is essential when choosing the right box for a product. These considerations work together to determine the best packaging solution, ensuring the product's safe delivery while reflecting the brand's identity. A thoughtful evaluation of these factors enables businesses to make informed decisions, leading to efficient and protective packaging solutions that meet their needs.

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