Packaging is a component of almost every product. It fulfills several tasks. On the one hand, it protects the contents from impacts, scratches or moisture, and on the other hand, it makes the product easier to handle. This is especially true for small unit loads, liquids and bulk goods.

The packaging ensures that the product reaches the customer safely from the manufacturer. In the larger transport box or in the truck, it keeps the loss of space to a minimum. Finally, the packaging also serves to inform the user. This can range from sober facts to advertising messages of all kinds printed on it.

A particularly popular type of packaging is the folding box. It is the smallest packaging unit for a product. The folding box is therefore designed in a particularly elaborate way. This applies to both the imprint and the design.

In terms of folding box shape, the industry therefore offers much more than the standard cuboids. Depending on the product, these are also packaged in hexagonal or octagonal cylinders, octahedrons or even icosahedrons (twenty-sided cubes). There are no limits to creativity.

Basic information: What are the advantages of folding cartons?

Folding boxes are an inexpensive way to safely package a product until it is used for the first time. They protect the contents from bumps and scratches. This is especially important during production and transport. Since folding boxes also have a representative function, they are additionally provided with a sleeve made of thin plastic. This ensures that the imprint is not scratched and remains legible.

Folding boxes come in numerous shapes and designs. They are designed for lightweight content, so their carrying capacity is limited. However, this allows designers almost unlimited creativity that can be used to benefit the brand message. The design freedom is not only limited to the imprint and to the shape. The low load-bearing capacity also allows the inclusion of viewing windows and other useful or aesthetic applications.

Distinction between machine folding and folding by hand

Depending on the type, setting up a folding carton can become a challenge for machines. This is especially true for cartons with complicated closures. If tabs have to be inserted, an automatic folding machine quickly reaches its limits.

For small series, for example seasonal articles, the provision of a suitable machine is often uneconomical. The only option then is manual folding. This is much slower, but employees can reliably prepare even complex boxes for filling. In practice, the following types of folding cartons have become established:

• Pillow box
• Automatic bottom box
• Box with insertion flap
• Box with peg bottom

Pillow box is a particularly functional packaging. It consists of two sheets of cardboard, which is complemented on the side by two pairs of semicircular tabs. To set up, these tabs are pressed inside. The result is a container with curved outer walls, whose shape resembles a pillow.

The pillow box can be made quickly by machine and manually. It looks good and can be printed in many ways. Its disadvantage is that it cannot absorb compressive forces due to its curved shape. Therefore, it is packed tightly upright in its outer packaging.

Folding boxes with automatic bottom are particularly practical. The bottom of this type of folding box unfolds by itself as soon as the flat folded box is erected to the container. Boxes with an automatic base also have sufficient load-bearing capacity so that they can reliably transport even heavy contents. They are also well suited for manual and for automatic production.

Boxes with tuck-in flaps are usually cuboid-shaped. Their top and bottom sides are identical. They consist of two side flaps and a top flap extended by a fold around the tuck-in flap. Unlike the automatic or tuck-in bottom, a Folding boxes with tuck-in flaps hasthree elements that can support a load.

This makes this type suitable only for very light products. A common application is medicines. The technology of automatic nesting is extraordinarily fascinating in the insertion flap type. The precisely coordinated ballet of suckers, slides and guides ensures consistent quality and high output.

One Folding box with snap lock base is particularly load-bearing. A distinction is made in this type of folding carton between standard tuck bottoms and special bottoms, such as for moving boxes. The principle is similar in both cases. The bottom is inserted into each other in such a way that it acquires self-stabilizing properties. The normal standard push-fit bottom can also be processed by machine. Special push-fit bases such as those for moving boxes, on the other hand, are always assembled by hand.

The fastest, cheapest and easiest way to make a folding box resistant to moisture is adhesive film. These are available in an unlimited range of colors, effects, textures and designs. With a beautiful adhesive film you make your folding box not only water resistant, but also particularly aesthetic.

Pillow box fold

You fold a pillow box with the following steps:

1. Lay cardboard flat on a table.
2. Fold upper side flaps with thumb and forefinger until top curves up.
3. Fold the lower side flaps with thumb and index finger. Now the bottom also curves.

When making pillow boxes, it is best to take a suitable container. Place the folded boxes in it. Once they are secure, you can open the top again and fill them. When loading them with bulk goods, it is best to fill all the boxes gradually and at the same time. In this way, you prevent the full boxes from pressing in the neighboring empty box.

Automatic bottom box folding

You set up an automatic box like this:

1. Lay cardboard flat on the table.
2. Lift the top side upwards with both hands. The box stands up.
3. Press the automatically opened base into position from the inside. This keeps it stable.
4. Turn carton over, fill and seal.

Folding box with snap lock base fold

Folding bottom boxes are particularly stable. Proceed as follows for standard push-fit trays:

1. Unfold cardboard box and place on top.
2. Fold in the two triangular side flaps.
3. Fold in the C-shaped long flap.
4. Fold in the opposite trapezoidal long flap.
5. Slide the rectangular tip of the trapezoidal long lug into the recess of the C-shaped long lug.
6. Place the carton correctly, fill it and close it.

Here's how you build moving boxes:

1. Unfold the box and place it on top. To do this, fold the lids inwards so that they cannot be damaged.
2. Fold the striped side flaps inward.
3. Insert the tab behind the fold into the slot between the side tabs.
4. Repeat the process with the second long flap.
5. Turn carton over.
6. Fold the long flaps to the side behind the fold. The cardboard is thus perfectly formed and gets the full stability.

Make sure that you do not overload boxes with tuck-in bottoms. 10 kg is the maximum weight permitted for continuous loading. 15-20 kg is only permitted in exceptional cases if it cannot be avoided.

Folding boxes with tuck-in flaps fold

Folding boxes with tuck-in flaps are the most widely used type for primary outer packaging of goods. Their load capacity is limited, as they have only three instead of four flaps on the top and bottom. Their advantage is that you can open them from both sides. You build the Folding boxes with tuck-in flaps as follows:

1. Unfold the box.
2. Fold side flaps into center on one side.
3. Insert long lug with insertion lug into the slot between opposite wall and side lugs.
4. Set up the box, fill it and close it.

Folding boxes with tuck-in flaps are also a good start if you want to try your hand at making folding boxes yourself. All you need is a sharp knife, a ruler, some cardstock and some glue. However, making folding boxes can become an extremely creative hobby that can even earn you money.

Origami folding boxes for special occasions

If you already have crafting experience with folding boxes, then you can also dare the next step: crafting instructions for origami folding boxes are numerous on the Internet. They are particularly suitable as gift packaging. With them, you can make a great present for special people for a birthday or Christmas for little money.

There are hardly any limits to your creativity. Even simple pyramids with a triangular base stand out pleasantly from the other monotony of cuboid folding boxes.

These homemade gift boxes are ideal for gifts that also come from your hand. Jewelry, soap or candles you can also make yourself with a lot of imagination and little money. Thus, the folding box and gift complement each other perfectly.

If you use high-quality and strong cardboard, the folding box can also serve as a permanent storage place. With a waterproof coating, for example with a nice adhesive film, you also protect the cardboard from moisture and make it easy to clean.

Conclusion

Building folding boxes yourself can become a fascinating hobby. Besides building, decorating and designing a box is also extremely satisfying. What starts with simple, cuboid boxes with tuck-in tabs can be expanded to any number of things via origami boxes. Just be sure to be safe when tinkering. Scalpel and scissors should always be sharp, so you do not slip and cut yourself. We hope you have fun discovering this great hobby.

FAQ

1. Can you build folding boxes yourself?
   If you want to build a folding box yourself, we recommend that you start with the normal boxes with tuck-in flap. When marking out and cutting out, make sure that the edges are as precise as possible. Non-parallel edges always lead to a crooked, unattractive result. As with any hobby, practice makes perfect. Once you have a good command of Folding boxes with tuck-in flaps , you can venture into more challenging designs. There are almost no limits to your imagination.

2. Which folding boxes are the most stable?
   Folding boxes that are to be used without external support are particularly stable with a tuck-in bottom. This is especially true for the moving box design. However, make sure that you do not load a box with more than 20 kg if you want to move it by hand. For heavier products, choose palletized containers that you can lift with a forklift or crane.

3. Is manual production of folding cartons worthwhile?
   Folding cartons with tuck-in flaps or automatic bases can be processed very efficiently by machine today. A manual worker cannot cope with the output of these machines in any case. Therefore, as soon as large quantities are required, you should use the appropriate machine to obtain your folding cartons in sufficient quantity and consistent quality.