Technical Guides
Fundamentals of Corrugated Box Design
Basic principles for designing corrugated boxes that protect products and optimize costs.
Effective box design balances protection, cost, and functionality. Understanding design fundamentals helps specify the right packaging for each application.
Box Style Terminology
RSC (Regular Slotted Container)
Most common box style. All flaps same length, meeting in center. Efficient and economical.
HSC (Half Slotted Container)
One set of flaps only. Used with separate lid or when bottom must be assembled.
FOL (Full Overlap)
Outer flaps overlap completely. Better stacking strength and protection.
Die-Cut Boxes
Custom shapes cut from flat blanks. Used for retail-ready packaging.
Design Variables
Internal Dimensions
Length × Width × Height (L×W×H)
Must accommodate product plus cushioning
Consider insertion and removal ease
Board Selection
Single-wall vs double-wall
Flute profile (A, B, C, E)
Paper grades and weights
Based on product weight and fragility
Flap Design
Standard vs full overlap
Hand holes and ventilation
Closure method (tape, glue, staples)
Design Optimization
Right-Sizing
Minimize void space
Reduce dimensional weight charges
Use variable box sizes for product range
Strength Optimization
Longest dimension as length
Maximize perimeter for BCT
Consider print coverage effect
Cost Optimization
Standard sizes when possible
Efficient sheet utilization
Balance protection vs material cost
Testing Requirements
BCT (Box Compression Test)
Drop testing
Vibration testing
Actual shipping trials
Work with your converter's design team to optimize packaging for your specific products and supply chain.
More in Technical Guides
Corrugator Chrome Roll Cleaning Procedures
Clean corrugator chrome rolls on a locked schedule—remove starch film without scratching the surface or shifting glue-gap alignment after remount.
Adhesive Supplier Evaluation Checklist
Score adhesive suppliers on 15 plant criteria: TDS, trials, lot consistency, logistics, and true cost per bonded square metre.
Corrugator Roll Alignment and Parallelism
Measure corrugator roll alignment and parallelism to catch tilt, heat growth, and weak-edge bonds before they become scrap.