Corrugated boxes come in many different styles, each with its own pros and cons, as well as different pricing and assembly time. Corrugated boxes are broadly classified into two types - the ones that need custom tooling and the ones that do not.
Corrugated boxes that do not need any custom tooling are least expensive. They are available in predefined shape and sizes and you can simply order the size you need. One can procure boxes without custom tooling hassle-free and are a great way to kick-start your business. You can also custom print these boxes and pack them with custom printed packing tape. Boxes without tooling need some time during assembly. Mostly they require packing tape to close and seal the box. These boxes generally do not have tucks or tab locks to close the box. The two major variants are the Regular Slotted Container [RSC] and the Fully Overlapped Carton.
Regular Slotted Cartons are the most common style of corrugated boxes available in the market. All the flaps of the box are of the same length and they all meet in the middle so that they can be taped shut.
These are similar to the RSCs except, FOLs have the flaps that go from one edge of the box to the other. This requires more material to manufacture the boxes and hence they are slightly more expensive. However, these boxes are more durable and can bear heavier loads than RSCs.
With custom tooled boxes, you can create a box according to your own requirement. However, the time and cost overhead for the tooling is quite high. Boxes with custom tooling are profitable if you are shipping thousands of boxes in a week and you need to save packaging time.
Boxes with custom tooling have many variants. The most common is the Roll End Front Tuck or the Literature mailer. Not only is this style of corrugated boxes make a durable and secure container, but it also gives a better unboxing experience. These boxes can be sealed with a small amount of tape or even a sticker.
Another notable style of custom corrugated boxes is the box with a tab lock. A tab lock allows the top flap to be locked in place without additional materials. It can again be sealed with a custom sticker or printed packing tape.
All custom boxes come with two variants of the bottom. The auto bottom box does not need the bottom flaps to be tucked in manually and locks into place automatically when you open up the box.
The other variant where you have to manually tuck in the bottom flaps into each other is the tuck-in bottom flaps box. The auto bottom box saves time, but is slight expensive.
Now, finding the right style of the corrugated box depends on your budget and your preferences. If you are shipping thousands of boxes in a week, then you can go for boxes with custom tooling. Boxes without custom tooling are cheaper and can help small businesses cut costs on packing. Besides cost, another important metric to consider is the time needed to assemble or fold a box, pack the items and seal them. This can be overhead if you are shipping a higher volume of boxes.
Explore all kinds of packaging products and see which box is best for your business.