Slotted boxes Die-cut boxes Protective packaging Complex packaging

Complex corrugated packaging: custom structures designed for each application

Complex packaging is corrugated packaging with a structure designed entirely from the ground up, without relying on a standard FEFCO style, because the requirement exceeds the scope of a standard box in size, load, assembly mechanism or the test criteria it must meet. Each project begins with a brief based on actual operating conditions, and a prototype is produced before production.

Custom Engineering Custom Engineering example box structures in this group

Our process begins with your brief and the constraints of your operation. The Technical Service team designs the die-line and determines the box strength based on the product, the shipping method and how the box is stored and stacked, then produces a prototype for testing with your product before production. The process typically takes 14–21 business days.

Typical complex packaging projects

Corrugated boxes with special structures in many shapes and sizes, designed for individual jobs by Auto Boxes
Complex Packaging

Structures and assembly methods designed for each project

Every project in this group begins with the customer brief. Our team develops a new die-line and assembly sequence to suit the product, the shipping method and the storage and stacking conditions. When these conditions change, the shape, size and number of components change accordingly. The five types of requirement below are the most common.

  • 1

    Beyond standard size and weight

    Oversize / Heavy-Duty

    Products such as machine parts, motors and assembled furniture often exceed the capacity of a standard box. These projects typically use 5-ply BC flute board, with box strength determined by the product, the shipping method and the stacking height in storage.

  • 2

    Structures for specific loads

    Load-Bearing Structure

    Structures designed to distribute compression along the directions in which the product carries load, for example by increasing the load-bearing corners from four to six, or by reinforcing the side that carries the greatest weight. The approach varies with each product and stacking method.

  • 3

    Integrated mechanisms

    Handle / Lock-in

    Some boxes must function independently, with handles that support the weight for as long as the box is carried, integrated lock bottoms and tabs that assemble without glue or tape. These mechanisms are designed together with the structure from the outset, so no additional materials are required later.

  • 4

    Unboxing features

    Unboxing Design

    Gift boxes, premium seasonal packaging and luxury products make the moment of opening part of the brand experience. Our team designs pop-up structures, inner display tiers and a specific opening sequence for each design, ensuring they perform reliably in volume production.

  • 5

    Specified test criteria

    Specified Test Criteria

    Some projects include test criteria from the outset, whether export orders with criteria stated in the contract or domestic orders with conditions set by the customer. Our team incorporates these criteria into the brief at the design stage, then produces a sample for inspection before the cutting die is made. For dangerous goods that require UN-marked packaging, our team coordinates testing and UN marking for your box design.

Requirements outside these five types can also be assessed. The Technical Service team will review the actual product or a drawing with dimensions and weight, together with the shipping method and stacking height, then design the structure and produce a sample for testing with your product before production.

Assessing a complex packaging project

Spec Guideline

Indicators and information required before starting

Projects in this group are assessed on the requirement rather than the box type, as the structure differs for every project.

1. Indicators that a requirement calls for complex packaging
  • The product exceeds the size or weight a standard box can handle.
  • A specific mechanism is required, such as an integrated lock, a handle or features that create a brand experience.
  • The purchase contract specifies test criteria, or the product is classified as dangerous goods and requires UN-marked packaging.
  • The requirement has no clear solution yet, whether the challenge is shape, weight or use. The Technical Service team takes on requirements at this level and develops them into boxes that can be produced and used in practice.
2. Five items required before assessment
  • The product and its actual dimensions
  • Weight per item and per box
  • Shipping method: road, sea or air
  • Stacking height and storage method
  • Test criteria required by the contract, or the UN number of the product, if applicable
3. Pricing
  • There is no fixed price for this group, as the structure differs for every project.
  • Lead time from complete information to delivery is 14–21 business days, including design and sampling.
After receiving the brief, the Technical Service team designs a structure that meets it, covering the required strength, assembly on site and stacking in storage, then produces a sample for testing with your product before production. For projects that require a test report, our team coordinates the testing on your behalf.
Tips

💡 Internal and external dimensions differ by the board thickness

You may send the product dimensions, the internal dimensions of the box or the external dimensions of your current box. Please indicate which, as 5-ply corrugated board is approximately 4–8 mm thick, so internal and external dimensions always differ. With inner components such as dividers or trays, the space available for the product differs from the external dimensions even further.

Once we know how the dimensions were measured, our team accounts for board thickness, clearance for packing and unpacking, and the space taken by inner components, then prepares the die-line and produces a sample for testing with your product.

If you already use a box, the simplest option is to send the current box, or photos with measurements. Our team can then see how it allows for clearance and where it causes problems in use, and build on what already works without measuring everything from the beginning.

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FAQ: complex packaging

Yes. Send the actual product or a drawing with dimensions. The Technical Service team develops a new die-line from your brief and produces a sample for testing with your product before the cutting die is made.

The product or a drawing with dimensions and weight, the shipping method, the stacking height in storage and any specified test criteria. The more complete the initial information, the closer the first sample will be to the final packaging.

Approximately 14–21 business days from receipt of the brief to delivery, including structural design and sampling. Once the design is approved and the cutting die is made, repeat orders of the same design follow the standard production schedule of 7–10 business days.

Yes, including export orders with criteria stated in the contract and domestic orders with conditions set by the customer. Our team incorporates those criteria into the brief from the design stage. For projects that require a test report, our team coordinates the testing on your behalf.

The minimum quantity for this group depends on the structure and tooling required for each design. Our team assesses it and states it on the quotation for each project.