Corrugated box types: four groups and how to choose

Custom corrugated boxes fall into four groups according to how they are formed: slotted boxes, die-cut boxes, protective inserts and complex packaging. Moving from one group to another changes the upfront tooling cost and the lead time much more than it changes box quality. If you know the group before asking for quotes, you can describe the job accurately from the first inquiry and budget for tooling and time in advance.

The four groups at a glance

How to choose the right group

Three questions place a job in the right group, and none of them requires knowing box styles by name:

1. How much protection does the product need? Standard protection points to a slotted or die-cut box. If products already arrive damaged inside an intact outer box, look at protective inserts first, before changing the box. If standard designs have been tried without success, the job belongs in complex packaging.
2. Will you reorder the same box, and in what volumes? Large volumes of a standard box favor slotted boxes, the lowest-cost group. A die-cut box pays off once the reorders and the labor saved on the packing line are counted.
3. How much do appearance and shape matter on arrival? When appearance is a low priority, a slotted box does the job. A specific shape, such as a display pack, or a design that shortens packing time on the line calls for a die-cut box.

The first two answers place the job correctly in almost every case, and the third mainly settles the choice between slotted and die-cut. Settle the protection and reorder answers before comparing price per box.

Slotted boxes

Slotted boxes are the most widely used group in industry. A slotting machine cuts the slots and creases the fold lines directly into the board, so no cutting die is needed. They are fast to produce, carry no die cost and make the most efficient use of board, with little waste.

These are the five styles in this group that you can order from Auto Boxes, each with its FEFCO code. Four are slotted designs; the telescope box, FEFCO 0300, belongs to the FEFCO telescope type and is listed here alongside them.

FOL is the second most common style after RSC. For a closer comparison of the two and the other slotted styles, see RSC and FOL boxes: how to choose.

Die-cut boxes

Die-cut boxes are formed with a cutting die, which can produce curves, perforations, locking tabs and other shapes a slotting machine cannot make. Commonly ordered designs include:

• Tuck-end boxes with a snap-lock bottom, which assemble quickly by hand with no tape
• FEFCO 0427, where the side flaps fold in and lock to give a strong box without stitching
• Display trays and shelf-ready packaging (SRP), which travel as regular shipping cases, tear open along a perforated line and go straight onto the shelf
• Self-locking mailer boxes for e-commerce

Whether a cutting die is worth paying for depends largely on how often you will reorder. The die is a one-time cost charged with the first order, and later orders in the same design reuse it with no new die charge, so the more you reorder, the further its cost spreads. The size of the first order is only part of the calculation. Die prices depend on the length of the cutting blade and how intricate the cut lines are, and they vary between die makers, which is why the die is priced in the quotation for each job.

Protective inserts

Protective inserts are parts inside the box that hold the product still and spread the force of an impact. Movement inside the box is behind many cases of transit damage. It is a more common cause than an outer box made too thin, and an insert deals with it directly for less than the cost of making the whole box thicker. Crushed boxes and transit damage: finding the cause explains how to trace where damage comes from.

Glass bottles, cosmetics and ceramics are typically packed with partitions, the most popular type of insert. Notched board strips slot together into a grid, so each item sits in its own cell without touching the next. Other insert types include:

• Top and bottom pads
• Wall liners
• Product locks
• Corner protectors
• Tray and lid sets

Complex packaging

Complex packaging is for jobs that standard box styles cannot handle, so a new structure is designed for the product. Examples include hexagonal boxes, wrap-around boxes, boxes with carry handles, extra-large boxes built for heavy loads and multi-piece packaging systems that interlock.

The process differs from the other three groups because design and sampling come before production:

1. Measure the actual product, or work from its 3D file.
2. Design a new die-line.
3. Cut a sample on a plotter and test-fit the product before the production line is set up.

From receiving the brief to delivery, this typically takes 14–21 business days. Design and sampling usually cost less than the loss from a large run that turns out not to fit.

Choosing the board

The group settles the structure of the box. The board is a separate decision, and for every group the paper grade and flute are chosen as a pair. For the options, see Corrugated paper grades: what they are and how to choose the right one and Corrugated board structure: how E, B, C, BE and BC flutes differ.

All the box styles Auto Boxes produces are listed on Custom corrugated boxes.

Frequently asked questions

What are the minimum order quantities?
Unprinted RSC boxes start at 300. Printed RSC boxes start at 500 with flexo printing on one side; other print setups, such as printing inside and outside, are assessed case by case. Die-cut boxes start at 500 per size, offset-printed boxes at 2,000, and mailer boxes printed with your brand at 5,000 per size. All of these figures can be adjusted to the size and specification of the job.

Is a slotted box cheaper than a die-cut box?
Per box, a slotted box costs less. It also needs no cutting die, so there is no one-time die charge. Counted across the whole packing process and repeat orders, a die-cut box can cost less when you need a specific shape or want to shorten packing time.

Can I order without a box design?
Yes. Send us a product sample, or the product dimensions and weight. We design the die-line and cut a sample for testing before production.

How many colors can be printed?
Digital printing uses 4-color CMYK with no printing plate cost and suits small quantities. Flexo prints up to 4 colors and is used for logos and text on large runs. Offset prints up to 6 colors, CMYK plus spot colors, and gives the sharpest images. Its lead time is longer and is confirmed for each job.