There’s more to choosing a box than you might think. The right box makes all the difference when it comes to shipping your packages without damaging their contents.

Choose a Box Style

There are 6 major box styles to choose from:

1.Regular Slotted Container (RSC)

The regular slotted container is the most common box style and is often used for shipping and storage. The flap width (the distance from the outer edge of the flap to the folded edge adjoining the box) is the same on all four flaps. The two outer flaps meet at the center when the box is folded, and these containers require glue, tape or staples to close. These boxes are the most economical to produce and create very little manufacturing waste.

2.Full Overlap Container (FOL)

The full overlap container is similar to the regular slotted container, but has flaps that extend across the width of the box. This overlap provides reinforcement that results in increased stacking strength and offers protection against rough handling. This style is often used when there is a considerable difference between box length and width, creating a large gap between the inner flaps. The overlap helps to keep the outer flaps from pulling apart.

3.Half Slotted Container (HSC)

The half slotted container is similar to the regular slotted container, but has flaps only on the bottom, leaving the top open. Trays are often used as lids for these containers.

4.Die Cuts

Die cut containers incorporate special shapes or structural elements that cannot be achieved using the straight lines and right angle cuts of conventional scoring and slotting equipment. The unique designs of die cut boxes often involve angled or curved cuts, slots and scores, or other features, such as perforations and cut-outs. These designs are created using a steel-rule die to cut and crease the container into the final package.

5. Trays

These flat scored and slotted sheets have flaps on the sides and ends that fold and fasten to produce trays, which can be used by themselves or as lids for half slotted containers. Trays are often used to ship heavy, flat items and as reusable storage containers.

6. Pads

Pads are sheets of corrugated board that are used to protect or divide the contents of a box. They can be cut into any shape to help separate, cushion, suspend and fill irregular spaces within a container. Pads can also be placed against the inside walls of a box to offer additional stacking strength.

Choose the Right Box Strength

The strength of corrugated board determines how much weight a box can withstand. Board strength has traditionally been measured and expressed by its Mullen Test (also known as Burst Test). Recently, however, the Edge Crush Test (ECT) has become an industry standard for defining board strength.

Mullen Test

The Mullen Test determines the force, measured in pounds per square inch, required to burst or rupture corrugated board using hydraulic pressure. Burst strength indicates an individual box's ability to withstand internal or external forces, and to contain its contents during rough handling. A designation of 200 indicates that the board burst after 200 pounds per square inch of hydraulic pressure was applied. Of the two types of test board, Mullen Test board is considered stronger and of better quality.

Edge Crush Test

The Edge Crush Test measures the ability of corrugated board to resist top-to-bottom compression. The test is usually conducted by stacking weight on top of a carton until it crushes and is also measured in pounds per square inch. A designation of 32 ECT indicates that the board, standing on edge, can withstand a force of 32 pounds per square inch before crushing. The higher the ECT number, the more compression the box can withstand.

The Mullen Test relates to the containment and handling abilities of a box, while the ECT relates to a box's stacking strength and ability to hold up during distribution and transportation. While these two tests measure different abilities of a box, both tests are considered accepted methods of denoting box strength. In a single wall corrugation, 200 Mullen correlates with 32 ECT, and 275 Mullen correlates with 44 ECT. In a double wall corrugation, 275 Mullen is somewhat comparable to 48 ECT.

How to measure a Box?

Box measurements are always expressed in three dimensions—length, width and depth—and always in that specific sequence. The length and width are the opening dimensions of the box, and the length is always the larger of the two (unless they are equal). The depth is how far you can reach into the box, and is the distance measured perpendicular to the length and width. These measurements always relate to the inside dimensions of the box.