A Complete Guide for Carton Packing Machine

09 Jun.,2025

 

A Complete Guide for Carton Packing Machine

Welcome to this article, which is an in-depth guide to carton packing machines, If you’re looking for any information about carton packing machines, you will find it right here. So keep reading to learn more.

Read more

1. What is a carton packing machine?

A carton packing machine is a machine for mechanized measures to pack cartons. A carton packing machine, also known as a carton packaging machine, is the use of a machine to automatically wrap cardboard containing glass bottles, PET bottles, cans, large bottles, etc, suitable for beer, beverages, condiments, and food. And other machines all use professional display control. The carton packing machine is greatly convenient to operate and is indispensable equipment for automated large-scale production, which can greatly improve product packaging efficiency.

2. What is the mechanism of carton-packing machine?

There is some mechanism of carton packing below:

  • Container inlet: On the inlet conveyor belt platform, the garden-column type container is divided into multiple lines by the divider plate and the pneumatic vibration rail, while the single-lane entry and special shape of the container are divided into multiple lines by the separation gate.
  • Container divider: The container divider is driven by two motor drives to gently and evenly separate the containers. To handle containers that are not stable enough, such as five-jaw PET bottles, transition channels can be used between conveyor chains. After the containers are grouped, they are pushed out by the pusher.
  • Cardboard inlet: The cardboard is neatly stacked on a roller conveyor belt and then automatically guided into the lifting cardboard storage located below the container inlet. The vacuum jaw extracts the top piece of cardboard from the lifting memory and places it horizontally on the cardboard inlet.
  • Package forming device: The cardboard is transported under the container group and the ends are mechanically folded. The side cover is folded in with a rotating copper, coated with hot melt by the nozzle, and glued to the bottom cover.
  • The circulating sealing chain presses against the bottom cover and carries the package through the wrapping machine.
  • The top cover is then folded off and glued to the sealing edge.
  • Finally, the sealing chain closes the top cover from above. Since the package runs longitudinally and the bottom is already firmly glued, the top cover can be glued very accurately.

3. What are the components of carton packing machine?

There  are some components below:

1) Fuselage

The fuselage is the rigid skeleton of the packaging machine, which mainly plays the role of supporting and positioning each component. All mechanisms or devices are installed on top of it. The fuselage must be stable and the center of gravity as low as possible to facilitate smooth mechanical operation. The material, structure, shape, decoration, etc. of the fuselage are designed according to the use and characteristics of the packaging machinery.

2) Control system

The function of the control system is to control the relevant parts of the packaging machine and coordinate their process functions. Complete the packaging on time and in order. The devices of the control system mainly include photoelectric control, electronic control, electro-mechanical control, pneumatic control, jet control, etc. The most common system of these is electro-mechanical control.

3) Power part

The power part is the power source of packaging machinery, which can be a motor drive, hydraulic drive, air pressure drive, etc., and is mostly used to drive by an electric dynamo.

4) Transmission mechanism

The transmission mechanism varies from different models and transmits power and movement to various actuators, control elements, auxiliary mechanisms, etc. Its main transmission components are gears, ratchets, cams, sprockets, belts, worm gears, screw nuts, etc.

7) Actuator

The actuator is the core part of the packaging process operation and auxiliary operation and often uses movable mechanical components or manipulators to realize packaging operations. The packaging process operation mainly includes molding, filling, wrapping, sealing, labeling, etc.; Packaging assistance operations include the supply and transfer of packaging materials, packaging containers and products, and the output of finished products.

4. What are the applications of carton packing machine?

In the early stage of industrialization, the carton has always been packed by manual means, and with the development of large-scale mechanization, the corresponding more subdivided machine came into being, carton packaging machine is also formed in this process, replacing manual labor, the paper packaging machine is widely used in beer, chemical, food, medicine, and other industries, supporting in the filling line, etc., secondary carton packaging for all kinds of bottles and cans, greatly improving production efficiency.

5. What are the advantages of carton packing machine?

Compared with other types of packing machines, the carton packing machine we provide has the advantages below:

  • The modular construction of the machine provides a high degree of flexibility;
  • The linear arrangement of the machine makes the packaging of cartons particularly accurate;
  • Use the internationally renowned servo control system;
  • The control cabinet is pre-wired to make the start fast;
  • Short format change time;
  • It does not need to be maintained very frequently, and it is very durable;

Other information that you might need to know:

In order to create the greatest benefit for yourself within the specified time, it is necessary to ensure that your packaging production line runs well and there will be no errors in the production process, so as to avoid the impact of errors and failures as much as possible, and only then will the company obtain the greatest benefits.

The level of automation is constantly increasing in the manufacturing industry, and the range of applications is expanding. Automation in the packaging machinery industry is changing the way the packaging process works and the processing of packaging containers and materials. The packaging system that realizes automatic control can greatly improve production efficiency and product quality, significantly eliminate errors caused by packaging processes and printing and labeling, effectively reduce the labor intensity of employees, and reduce the consumption of energy and resources. Revolutionary automation is changing the manufacturing methods of the packaging machinery industry and the way its products are transmitted.

The design and installation of automatic control packaging systems have shown a very obvious role in improving product quality and production efficiency in the packaging machinery industry, or eliminating processing errors and reducing labor intensity. Especially for the food, beverage, pharmaceutical, electronics, and other industries, it is crucial. Technologies in robotics and systems engineering are being further deepened and more widely used.

6. What are the characteristics of carton packing machine?

There are some characteristics below:

1) Packaging form

automatic transmission, unpacking, boxing, batch number printing, sealing, waste removal, and other characteristics, compact and reasonable structure.

2) Easy to operate

servo/stepper motor, touch screen, PLC programmable control system, man-machine interface display operation is clearer and simpler, high degree of automation, more humanized;

3) Wear protection

the frame and plate have sufficient strength and rigidity, the frame is equipped with the main drive motor and clutch brake of the machine, the machine plate is equipped with various transmission systems, and the torque overload protector can realize the main drive motor and transmission parts in the case of overload to protect the machine parts from damage.

4) The height is configurable

The machine can adjust to different heights to accommodate different sizes of packages so there is no need to change machine molds. It means that one machine can be used for many purposes that show incredible flexibility and versatility of the machine. Generally, it is suitable for all types of corrugated cardboard or lithographic laminated boxes, allowing the operation of a wide range of box types.

5) High safety

if there is no product – the box will not fall, and the machine will automatically stop and sound an alarm.

  • The automatic photoelectric detection and tracking system is adopted to save packaging materials, and the box body will not fall due to empty materials
  • The vacuum suction cup used by this machine is a ZL112 vacuum generator (SMC), automatic vacuum box taking, wide angle unpacking, to ensure the unpacking accuracy
  •  It can be produced with an aluminum-plastic packaging machine, pillow packaging machine, 3D packaging machine, filling line, filling machine, labeling machine, ink-jet printer, online weighing machine, other production lines, and other equipment.
  • According to customer needs, design an automatic feeding machine, and box entry system.
  • According to customer needs, you can choose hot melt adhesive machine sealing, such as hot melt adhesive spraying machine, or mechanical brushing. 

7. How to operate carton packing machine?

Here we provide you with four major operation steps of packaging machines and their precautions:

1) Firstly, place the packaging machine material in the right position.

We need to prepare the materials of the packaging machine, such as your products, your packaging containers, the materials of the products, etc., and put them in the corresponding positions for the normal use of the packaging machine.

Notes:

It should be noted here that before using the packaging machine, it is necessary to ensure the cleanliness and hygiene of the packaging machine, especially the packaging machine with filling technology, which is easy to hide dirt, thus causing secondary pollution of the product. In addition, the packaging container should fit the specifications and dimensions of the packaging machine.

2) Secondly, turn on the power switch of the packing machine.

After we have prepared the materials and containers used in the packaging machine, then turn on the power switch of the packaging machine, and the packaging machine is officially started.

Notes:

It should be noted here that before opening the power switch of the packaging machine, it is necessary to check its power line, if the power line has exposed places, it is necessary to replace the power cord in time, otherwise, it is easy to cause the risk of leakage, and at the same time, it is also very easy to damage the packaging machine equipment.

3) Thirdly, packaging machine parameter setting is another important step.

After the power of the packaging machine is turned on, the touch screen of the packing machine will also start, we have to click to enter the parameter setting of the packing machine, according to the instruction manual of the packaging machine to set the temperature, sealing time, sealing speed, filling capacity value and other parameters to ensure the normal use of the packaging machine.

Notes:

It should be noted here that the parameters of the packing machine must be set according to the instructions of the packaging machine, for example, the sealing temperature of the packaging machine is 200 degrees, if the temperature is set below 200 degrees or higher than 200 degrees, there will be bubbles in the seal or the phenomenon of the improper sealing film.

4) Finally, the packing machine starts to operate.

When everything is ready, the packaging machine can be officially started, directly press “start” on the main menu, and the packaging machine can run normally!

Notes:

During the start of the packaging machine, we must observe the temperature of the machine at any time, if the temperature is overheated, we should stop the operation, and wait for the packaging machine to cool down for half an hour before the operation, so as not to cause the packaging machine equipment failure due to excessive temperature. In addition, if the packaging machine has abnormal noise during operation, the packaging machine should be turned off immediately and started after inspection and maintenance.

8. How to choose a carton packing machine?

First of all, you need to determine which products you will pack in the packaging machine you will buy. Packaging machinery manufacturers generally have a variety of products, but some clients in the purchase of packaging equipment, hope to be able to package their own all types of products through a device. In fact, this is a very wrong idea, because generally speaking, the special machine than the compatible machine packaging effect is better. The variety that can be packaged by packaging equipment should not exceed 5 varieties, and the products with too large size differences should be packaged separately.

As far as possible, choose a machine with simple operation and maintenance, complete accessories, and automatic continuous feeding, which can improve packaging efficiency and reduce labor costs, which is suitable for the long-term development of enterprises.

Choose a long-established packaging machine enterprise as much as possible, and the quality is guaranteed. Choosing a machine produced by a mature technology and stable quality enterprise can basically achieve the effect of a faster and more stable machine, low energy consumption, low manual work, and low scrap rate. In the process of use, if you buy a low-quality machine, the packaging film that accumulates and wastes in the future daily production is not a small amount, especially now that the packaging materials are rising.

In terms of after-sales service, the “circle” should have a good reputation. After-sales service is timely and on call, especially important for food processing enterprises for which the freshness of the products is of great importance.

If there is a field investigation, we should pay attention to the big aspects, but also pay attention to the small details, often details decide the quality of the whole machine. Bring samples for testing whenever possible

9. What’s the normal price of the carton packing machine?

The price of a common carton packing machine usually is hundreds of dollars. But there are very expensive carton-packing machines available. Their machines may have some advanced features or the production procedure is very complex.

10. What are the factors that determine the price of carton packing machine?

There are some factors below:

1) Brand factors

Just like different brands of notebooks, in the case of configuration, appearance, performance, etc., the price of notebooks is generally much higher than that of other brands of notebooks. Just as it is said to believe in the power of the brand, everyone feels that buying branded things makes people more assured.

2) Machine Quality

The quality of the product itself is the basic factor that determines the price. Including the value of various accessories, whether the life and use method of accessories are perfect, the technical content contained in the product, and other information, the quality determines the price of the sealing machine.

3) Market factors

The automatic sealing machine on the market is more popular and has strong demand, which will affect the price of the sealing machine to a certain extent, and the impact of this factor will be reduced due to the sufficient supply in the market. Similarly, in the annual sales season, the price of this machine will be higher, and this market-oriented price fluctuation will not have a substantial impact on the price. However, enterprises can also choose a reasonable time when purchasing machines to avoid these unnecessary passivities.

4) Marketing strategy

All the goods on the market have their own marketing strategies, some of which are not noticed by everyone, but they are reflected in the price.

5) After-sales service system

With the continuous progress of society, people’s sense of service has been slowly cultivated. Now no matter what product you buy, if there is no good after-sales service system, then your product has already lost half. Therefore, when consumers choose a sealing machine, they would rather spend more money and buy a sealing machine from those companies with good after-sales service. Because if the machine encounters problems in the future, then it is also a good guarantee to find after-sales solutions.

11. What are the common problems that may arise on carton packing machine?

There is sometimes occurred that the electromagnet of the machine does not absorb. The cause of this failure is mostly the internal fault of the host, the solenoid coil being blown out, the line interruption, and other reasons.

The solution is: first check whether the host is internal or external problems;

Secondly, check the electromagnet fuse, check whether the electromagnet has signs of power, eliminate mechanical jamming, and detect the internal power supply when everything is normal; Often encountered in the weighing packaging machine is the cause of this failure: sensor damage, bridge voltage failure, line connection or interruption is wrong, the elimination method is: detect the load signal of the sensor and the connection or host, close to detect the bridge and amplification circuit or computer output display circuit, sometimes there will be poor system stability resulting in unstable bag volume to solve this problem can test whether the line is in good condition.

However, the weary of parts in use and poor lubrication will cause damage to parts and may expand the occurrence of faults and accidents, so it is very important to quickly find and eliminate faults. Don’t turn to the manufacturing plant for a glitch and win valuable time and money.

Here are a few places and repair methods that are prone to failure:

  • Fault: Cut the steel strip
  • Causes:

1) Cutter wear or failure

  • Maintenance method: check whether the cutter or cutter holder is worn or faulty, if the wear is serious, it should be replaced

2) Air pressure decreases

  • Maintenance method: check whether the working pressure is normal;

The cutting steel belt force comes from the blockade cylinder see fault phenomenon;

Check the blocking operation:

  • Fault: The locking clamp is not subjected to enough pulling force
  • Cause: Clamp block connection holes or connection pins are worn
  • Repair method: Check these parts when the groove depth is shallow and replace them if necessary.

12. How to maintain carton packing machine?

A machine only operates better if you take good care of it. Asides from the daily operations, you also need to pay attention to taking good care of it. The maintenance methods we would like to provide you with include:

  • Remove the chips or dirt in the machine once a week.
  • Once a month, clean and lubricate the upper skateboard, the middle knife, and the front top knife mentioned in the previous section.
  • After doing the above two maintenance once every three months, add some lubricating oil to all (shaft, core) and bearings.
  • Replenish the oil in the wheel box of the reducer once every two years.
  • It must be noted that several parts cannot be refueled: a send-back with rollers.
  • Every time you refuel, do not add too much, so as not to cause the failure of the microswitch due to immersion in oil.

Glance in any pantry, peek into any fridge, look into the far reaches of a closet. 

Guess what you’re more than likely to find?  

Carton boxes.  

That’s right. The not-so-humble carton box is everywhere.  

Cartons house our milk, our cereals, our cosmetics, our kids’ toys, our electronic items – and so many of the other everyday necessities that constantly arrive in our homes.  

They’ve been around for eons and show no signs of disappearing.   

In fact, demand for cartons is on the upswing. According to Grand View Research, the folding carton packaging market size is predicted to be $171.35 billion by . And not all of this growth is coming from the US. Thanks to a growing middle class, the Asia Pacific folding carton packaging market is expected to reach nearly $80 billion by . 

More and more companies are realizing that the functionality, affordability, and aesthetics of carton boxes are hard to beat. 

Carton boxes protect the goods inside, are easy to open and use, are cost-effective, and they can attract a buyer’s attention. That’s quite an impressive resume for a simple folded piece of cardboard

Now, let’s dig deep into the world of carton boxes and see what they can do for you.

Carton Boxes Defined

Is a carton, a box? Most definitely. But a box isn’t necessarily a carton.  

We know, it’s confusing. 

Definitions of cartons vary, but rigid boxes or heavy-duty corrugated boxes generally aren’t considered cartons. And boxes made of materials, such as wood, aren’t usually referred to as cartons in the industry. 

To add to the confusion, cartons also go by various names. Sometimes carton boxes are called paperboard boxes, chipboard boxes, or folding carton boxes. 

But whatever you call them, you’re bound to find them in your pantry, your bathroom, and all over your house. 

There are many different definitions of cartons floating around, but one most can agree on is this: 

What are Carton Boxes?

A carton is a folding box that’s typically made from paperboard. To form a carton, the paperboard goes through a cutting, folding, lamination, and printing process before it’s sent flat to whoever is going to fill the cartons with products.

A Brief History of Carton Packaging Boxes

It’s hard to remember a time when grocery store or big box store shelves weren’t crowded with row upon row of colorful carton boxes – all vying for our attention.   

The first carton boxes looked a little different than what we have today. 

Charles Henry Foyle is credited with inventing carton boxes back in the s. He used a piece of paper that was cut in such a way it could be folded to form a box.  

Initially, these boxes were held together by strings and tacks. As you can imagine, it was a very laborious process to make them, not to mention expensive. That’s why, in the old days, cartons were reserved for special luxury items, such as jewelry. 

This all changed when in , Robert Gair accidentally discovered that his printing press could be used to mass-produce carton boxes. From then on, the carton box industry began to take off and has never looked back. 

With mass production, even simple everyday items could be packaged in cartons. This served a practical purpose – the carton packaging protected the items and gave them a longer shelf life. Cartons also provided a whole new way for companies to place their branding front and center. 

Benefits of Carton Boxes for Packaging

If you’re looking for a practical, beautiful, environmentally-friendly box to hold your goods, then carton boxes are the way to go. 

The Practical Side of Carton Packaging Boxes

First and foremost, the custom packaging needs to be functional. Let’s take a look at some of the practical benefits of carton boxes:

  • They make efficient use of space. They’re lightweight and, because they fold flat, they can be easily stacked. This saves space in the warehouse.

  • They offer ease of use. Folding designs make it easy to open and reclose packets.

  • They’re suitable for automatic packaging. This makes it easy to fill and seal with automated machinery.

  • They’re inexpensive. It’s not just the physical materials that are cost-effective.  Since cartons are lightweight and fold flat, they

    save on shipping costs

    .

  • They offer tons of flexibility. Cartons can store all sorts of shapes, even liquids.

  • They’re strong and durable, so cartons keep products safe.

  • They can deter crime. Some companies are incorporating anti-theft and anti-counterfeit measures into their

    custom carton boxes.

    Grand View Research found that

    companies are increasingly using RFID

    (radio frequency identification) and embedded barcodes in cartons as a way to deter counterfeiters. 

Shop Popular Products

Custom Mailer Boxes with Logo
Learn More
Custom Soap Boxes
Learn More
Custom Vape Cartridge Boxes
Learn More
Custom Hair Extension Boxes
Learn More
CBD Boxes
Learn More
Customizable Candle Box Wholesale
Learn More
Pillow Boxes
Learn More
Custom Printed Eyelash Boxes
Learn More
Custom Cardboard Boxes & Cardboard Packaging
Learn More
Custom Printed Product Boxes for Retail
Learn More
Custom Lip Gloss Boxes
Learn More
Custom-Made Lip Balm Packaging Boxes
Learn More
CBD Display Boxes
Learn More
Custom Bath Bomb Boxes
Learn More
Custom Collapsible Boxes
Learn More
Custom Kraft Boxes
Learn More
Custom Printed Medicine Packaging Boxes
Learn More
Custom Hanger Boxes
Learn More

Folding Carton Boxes are Easily Customizable

Carton boxes are indeed functional, but don’t confuse that with being boring and simply utilitarian.  

You can infuse your carton packaging boxes with whatever personality you like and let your creativity shine. With an eye-catching carton design, you can set the retail boxes for your company apart from the competition.

A carton box is often your customer’s first impression of your brand. And we all know how important that is. Some research even suggests that people form first impressions in about 17 milliseconds. Now that’s fast.

Lucky for you, cartons are conducive to beautiful packaging design. Carton boxes were made to embrace the wow factor. Paperboard surfaces are printer friendly so it’s easy to incorporate eye-catching, colorful designs. You have many options with high-resolution graphics and can incorporate two-sided prints onto the cardboard carton boxes. 

You can let your creativity run wild – or you can hire a designer at just about any price point to get you started.  

Check out sites like Behance or 99designs that showcase designer’s portfolios. A quality designer can create a carton mockup that will help you find the right box size, shape, and colors to beautifully showcase your product. 

There’s also the more practical side to the easy printability of cartons. 

You can include product information right on the box. This is a major plus for food packaging, where detailed nutritional information can be printed right on the box.  

Ever been in the grocery aisle trying to decide between two competing kinds of cereal? 

We all know to flip to the side panel and boom. There’s all of the information we need to decide which one to grab. 

The versatility of carton box design is not just limited to graphic images. Cartons can easily be made into different shapes and sizes. You’re not limited to a predictable cube shape.   

You can also add other marketing options, such as cut-outs, that add interest and offer a sneak peek of the product.

The Environmental Benefit of Paperboard Cartons

Nowadays, a company that doesn’t take environmental concerns seriously, does so at their own peril. 

As consumers are becoming all-too-aware of the damage we’re doing to the environment, eco-friendly packaging is quickly becoming a must have component for brands.  

Consider that in , global plastic waste volume reached nearly 6.3 billion metric tons. This figure is predicted to increase to 12 billion metric tons by . 

No wonder single-use plastic containers have fallen out of favor, and are even banned in many instances. Even China, which is one of the world’s largest consumers of plastic, has said it will ban non-degradable bags in major cities by the end of and in all cities and towns by .

As a result of the world’s waning appetite for plastic, companies are increasingly turning to the old standby – carton boxes. Let’s look at some of the environmental benefits that carton boxes offer: 

  • Paperboard can be easily recycled. It’s non-toxic and can be reused. Carton boxes are also easy to break down for recycling, and consumers are more likely to make the effort to recycle. According to the EPA,

    around

    44.2 million tons

    of paper and paperboard were recycled in for a recycling rate of 65.9 percent.

  • Many carton manufacturers follow

    SFI

    and

    FSC

    certifications, which promote forest sustainability.

    Carton manufacturers

    are required to do their part, such as planting trees to replace the ones they’ve cut down.

  • Many manufacturers of custom carton boxes are also making use of recycled paper pulp and non-wood pulp.

  • Carton boxes are usually shipped flat, which cuts down on the amount of fuel needed to get these boxes to their destination. 

Drawbacks of Carton Boxes for Packaging

Of course, nothing’s perfect. Sometimes a carton box can’t fulfill all of your packaging needs and you’ll have to look at other options. 

Perhaps the biggest drawback of carton boxes is that they are not designed for shipping. Sometimes, carton packaging works well with your shipping and fulfillment needs, but note that cartons are not intended to be standalone or robust outer packaging.

Carton boxes are meant to be light-weight and easily stored. Unfortunately, to accomplish this, they have to sacrifice some of their strength. Carton boxes typically have a maximum thickness of 0.032 inches (.81mm), so they’re only meant to hold a few pounds at most.

Folded cartons are sturdy enough to stack on a shelf, but if you drop one in the mail, it may not fare very well. Cartons are generally meant for retail display applications – not to rattle around in the back of a delivery truck.

Most companies can’t rely solely on carton boxes for their goods. The carton packaging boxes may house the individual products, but to get from the manufacturer to store shelves, a supplier will need to opt for something a little stronger for transport. 

This is where corrugated boxes – which are much stronger – are a good option. Rigid boxes, which don’t fold or collapse, are also typically sturdier and can be used for certain applications when a carton box just won’t cut it. 

Common Folding Carton Box Styles Explained

After you’ve decided that you want to use carton boxes for your products, now comes the tricky part. It’s time to make some decisions. 

First, you need to determine which style will work best for your unique product. The options are almost limitless. There are so many different styles and sizes to consider, so your decision might feel daunting. You can truly go wild with your choices. And this is before you even think about the fun stuff like colors and fonts. 

Don’t worry. With a better understanding of what’s out there, you can find the right carton style for your product.  

Without further ado, let’s breakdown some of the most common styles of folding carton boxes:

Most Common Styles of Folding Carton Boxes

Tuck top boxes are one of the most popular folding carton box options. Here are some of the most common tuck top boxes you’ll find on the market:

  • Reverse tuck end (RTE) boxes

    have the closing panels (sometimes called tuck flaps) on opposite sides. One closing panel is on the front of the box, the other on the back. These

    customizable carton boxes

    are easy to assemble, store flat, and are cost-effective. Reverse tuck end boxes typically use a slit-lock tab to close the ends. They’re great for light-weight items, but can’t handle anything too heavy.

  • Straight tuck end (STE) boxes

    are similar to reverse tuck end boxes, except the

    tuck flaps are on the same side

    . This gives the box a cleaner look since you don’t see the raw edges. These

    customizable folded carton boxes

    are easy to assemble, store flat, and are great for light-weight items. They also typically use a slit-lock for secure closing. Straight tuck end boxes are usually a bit more expensive than the reverse tuck end boxes, since you get fewer boxes per paperboard sheet.

  • Lock bottom boxes (sometimes called 1-2-3 bottom boxes)

    are meant for heavier items. They usually have a tuck top closure. As with the above-mentioned styles, these box cartons also store flat. Lock bottom boxes stack well and look better on the shelf since they have a flat bottom.  A lot of food items come in these types of box cartons. One drawback is they’re typically more expensive than some of the other carton box options.

  • Crash bottom boxes (sometimes called auto-lock bottom boxes)

    are pre-glued on the bottom for extra strength. They have a bottom that goes into place automatically. Auto-lock bottom boxes also store flat and can be assembled and loaded quickly. Crash bottom boxes are usually more expensive, since the

    carton box manufacturer

    has to take the extra step to glue the bottom.  

  • Top tuck boxes 

    are what you might think of as a cake box, but they’re not just for pastries. These boxes offer a creative way to display other light-weight items, such as clothing or multiple small items. You can even add a little window to your top tuck boxes, so your customers can get a peek at what’s inside (see window patching below).

  • Five-panel hanger tab boxes

    are like the reverse tuck end boxes, except they have a longer hanger panel that extends from the back panel. These offer a simple solution to display lightweight products in a retail setting. These

    custom boxes

    can be easily modified to include cut-outs, to give customers a better idea of your product. If you visit a pharmacy, you’ll see all kinds of products that utilize five-panel hanger tab boxes – everything from cosmetics to crayons (as shown in the following image). 

Your head might be spinning, but hang in there. Let’s switch gears and look at a handful of common features you may want to add to your folding carton box:

  • Adding Inserts:

    An insert is a piece of paperboard that is folded, or sometimes glued, to fit in your box to secure loose items. This is a useful feature if you have fragile items or multiple items that you want to prevent from crashing around in the carton.

    Custom inserts

    can work with any folded carton type and are easily customizable to fit whatever random-shaped article you’d like to secure.

  • Custom Cutouts:

    This is when you cut out part of the paperboard to show what’s inside. Custom cutouts can be made in any shape, so it can reflect your brand.

  • Window Patching:

      If you want to go one step further than a simple cutout, you could try window patching. Window patching is a thin plastic film that’s attached to the die-cut window (you’ll see this as part of your

    dieline

    as well). These windows are usually reserved for higher-end products and are often used to showcase

    food and beverage items

    , so customers can get a glimpse of the quality inside.

    Of course, one drawback with window patching is it uses plastic, which isn’t as

    environmentally friendly

    as paper products and may turn off some customers.  That’s why it’s so important that you know your customers and you make sure your

    retail packaging

    reflects your brand.

  • Thumb Tabs:

    Thumb tabs are those little circular cutouts made in the main panel of the carton packaging to make the box easier to open.  

Practical Design Considerations for Carton Packaging Boxes

When you think of packaging design, your mind probably jumps to the fun stuff. 

What colors should I use? Where should I put my logo? But first, there are a few practical aspects of design you need to consider. Some of the most important elements to consider are your material selection, paperboard thickness and cost considerations. Let’s jump in.

Selecting Materials for Carton Boxes

Before speaking with you carton manufacturer, one of the first decisions you’ll need to make when designing your carton boxes, is what material do you want to use. 

Here are a few of the most common materials used for carton boxes:

Soontrue contains other products and information you need, so please check it out.

  • Solid-Bleached Sulphate (SBS)

    :  SBS is made from bleached chemical pulp.  It’s a medium density board that’s coated on the top surface and sometimes on the reverse side as well. It’s white both inside and out, so it has excellent printing qualities. High-end graphics will look crisp on this material.

    SBS is also hygienic, doesn’t impart any smell or taste, and is approved for food contact. That’s why SBS is a popular choice for goods, such as chocolates, cigarettes, and perfumes. A bonus is it’s recyclable and relatively inexpensive. 

  • Clay Coated News Back (CCNB)

    : CCNB is a recycled board that’s made out of a blend of recycled newsprint, old corrugated containers, and mixed secondary paper. It’s less rigid than the SBS board. It has a glossy coated surface on one side and is grey/brown on the other. 

    CCNB is cheaper than SBS, but it has some disadvantages. Since it’s not a pure white color like the SBS board, it’s not as effective for printing and you’ll have to compromise a bit on the graphics quality. When it comes to colors, remember to discuss the differences between

    RGB and CMYK

    and

    Pantone colors

    with your manufacturer.

    CCNB also absorbs water, which means it needs to be kept dry. But if you’re looking to make low-cost

    folded cartons

    where recycled content is preferred, then CCNB may be the option for you. 

  • Natural Kraft or Coated Unbleached Kraft (SUS or CUK)

    : This is made from 100% recyclable materials. CUK is coated with a polyethylene resin, which is safe for food. Kraft paper is also strong, durable, and resistant to tearing, which makes it a good fit for items like heavy beverages.

Paperboard Thickness for Folding Cartons

Next up, you need to consider the board thickness (the caliper). 

Paperboard comes in many different calipers, so you’ll have to make some decisions about what thickness is best for your product.  

It needs to be able to hold the weight of your product, but you also want to consider the assembly process as well. You don’t want to waste money and efficiency on an overly-thick board. 

To give you an idea of the thickness of a standard paperboard box, such as a cereal box or a mac and cheese box, those generally fall in the .016 or .018 caliper range. A counter display may use a more robust .024 point thick board.  

Cost Considerations for Carton Boxes

Of course, you don’t want to neglect the bottom line when designing your carton boxes.  

Most of the time, custom boxes cost less than you probably think. But that’s not always the case. You’ll want to weigh the cost of the materials and manufacturing efficiency. And sometimes, it pays to spend a little more. 

Consider whether you want to use offset printing or digital printing. Offset printing is often considered the go-to choice for bulk and wholesale custom packaging, but it’s not right for every company’s needs. 

Your choice might be slightly more expensive, but if it’s in your budget, it may be worth the splurge. It gives a higher-end look since you have more options with graphics and colors. 

Another thing to keep in mind is to take into account the scalability of any options you choose. The printing process is usually cheaper the more you order, so you may want to place a larger order all at once, rather than several smaller orders. 

Also, remember that old adage, time is money. You’ll want your cartons to be easy to fill with your product. An overly-intricate carton may look cool, but if it’s difficult to get your product in there, it’s probably not worth it.

Carton Box Design: Make Your Packaging Beautiful

Now for the fun stuff. Making your custom carton boxes beautiful and getting them noticed on a crowded shelf. 

Matte or Gloss Lamination: The Finishing Touch

One important aesthetic decision you need to make about your carton box is what kind of finish do you want. This is the lamination process, which is a protective layer that gives your box that finished look. You can choose between a matte or gloss lamination:

  • A

    matte finish

    doesn’t reflect light, so it doesn’t have a sheen. It’s somewhat understated, but can give a sophisticated look. Scratches are less noticeable with a matte finish.

  • With a

    gloss finish

    , light bounces off the surface, so it looks shiny. It’s more “in your face” than its more subdued counterpart. Gloss finishes are good at resisting dust and fingerprints. 

Either finish can look great and both have their pros and cons. It all depends on what message you want your custom carton boxes to convey. 

Learn more about finishing options to make your product packaging stand out. Read up about UV coating, soft touch coating and lamination, spot UV, embossing vs debossing and aqueous coating for a quick primer.

Branding: Printing Your Logo on Custom Carton Boxes

There are so many design elements that you can incorporate into a carton box, but the important thing is to not overdo it.  

It’s fine to use bold colors or some crazy fonts, but you don’t want to overload your customer’s senses. Sometimes it’s a fine balance between capturing a customer’s attention and turning them off with too much noise. 

Also, remember that your custom packaging is an extension of your brand and needs to reflect your company’s values.  It’s important to keep your branding consistent over all of your platforms – whether it’s your website or the packaging boxes that store your goods. 

Here are some common branding elements you might want to include on your carton packaging boxes:

  • Your logo.

    You’ve no doubt put a lot of thought into that baby and it should have pride of place.

  • Your colors.

    Even if your company doesn’t have a set color scheme, you should put some thought into what colors you want for the

    box design

    of your carton. Are you going for an earthy feel? Then go with muted, natural colors. Looking to convey some fun? Then go bold.

  • Use materials that reflect your company’s values.

    If the environment is important to you – make sure your cartons reflect that. 

  • Typography.

    Use a font that stays consistent with your brand identity. Don’t use a boring, staid font if you’re looking to project whimsy.

  • Shapes.

    With cartons, you’re not limited to cubes. Look at Toblerone, the classic Swiss chocolatier. Chances are that you’d recognize the iconic chocolate bar just by the shape of the box.  

Read more about how to nail packaging design with our guides on ecommerce packaging, cosmetic packaging design and the unboxing experience to help get those creative juices flowing.

Carton Design Inspiration and Examples

Carton boxes come in all shapes, sizes, and colors. 

The choices can feel overwhelming. That’s why it’s sometimes useful to look at what other brands are doing. You don’t want to copy, just pull a little inspiration.  

Here are some examples of companies that are using custom carton boxes to effectively reflect their brands. 

Burlington Socks

Who said that socks have to be boring?

This fun carton design for Burlington socks adds a clever twist to a globally known product. 

Rather than using a usual cube shape for their sock boxes, they went with an unexpected sandwich box. The fun colors and bold font also give the carton packaging boxes a playful edge. 

Sojos

Sojos makes naturally nutritious raw pet food and gourmet treats. 

They incorporated many of the product packaging design elements we touched on earlier in their dog treat boxes. 

Sojos uses bold colors, has a window to offer a look at what’s inside, and even have a handle that can double as a hanger tab. 

It may only contain dog treats, but this box just exudes quality and fun. 

Crabtree and Evelyn

A carton box doesn’t need to be a crazy shape to command attention. 

Crabtree and Evelyn used an understated, yet eye-catching box design for their volcanic ash face mask. 

The carton matches the container inside. The sophisticated black background with white lettering and a simple gold image shows you don’t need to overdo the colors and graphics to make it stand out.  

The box radiates a sense of adventure, which is true to the company’s self-proclaimed vibe.

Beso Del Sol

Unlike a corrugated box, cartons aren’t limited to only containing solids. 

Beso Del Sol’s fun, sangria-filled, cartons quite literally look like a party in a box. 

When it comes to carton packaging, your imagination truly is the limit.

Lego

The classic blue Lego boxes may not be described as beautiful by many adults, but no matter what kind of carton you need, always remember your target audience.  

Lego plasters colorful, detailed pictures of their toys right on the box. They fill the front, back, and sides of the box with pictures of what’s included with the set. Kids want to see what’s inside.  

The larger carton boxes use close tabs so the toy can be stored back in the box when it’s broken down.  

Some Lego boxes have even become collectibles in their own right. 

Don’t believe us? Try searching “empty Lego box” on eBay.  

Get Started with Custom Carton Boxes

There’s a reason why carton boxes are so ubiquitous. 

And it’s understandable to have more questions than answers at this point. If you need help navigating through the carton boxes process, we’d be happy to speak with you. 

Refine Packaging has years of packaging expertise working with small businesses and Fortune 500 companies alike. Contact us today for a free quote on your custom packaging project. We’ll connect you with a live customer support representative who is able to answer any questions you might have.

Our team of designers are ready to help bring your artistic vision to life, who work hand in hand with our printing professionals that are ready to make your carton boxes truly shine.

Carton packaging boxes walk that delicate line of being both practical and potentially beautiful. 

Cartons are affordable, come in all shapes and sizes, can hold all kinds of goods (including liquids), are kind to the environment, and are a wonderful asset to your marketing arsenal. 

So, what are you waiting for?  

Start planning how carton boxes can help store and sell your products. There are so many carton options out there. You can come up with the right carton design to showcase your products at nearly any price point.  

Peruse store shelves for inspiration, choose what materials will work for your product, decide on the shape and size you need, figure out the logistics, and then pick out what finish and graphics you want. 

You can be as fancy as you want (or can afford). And don’t forget to have some fun.

Top 5 Challenges in Carton Packaging Production & How ... - IMPACK

8 out of 10 companies in the packaging industry whom we talk to face one or more of those 5 pressing challenges.  

And being the Director of Sales and Marketing at IMPACK, I hear about those challenges on a day-to-day basis.

Depending on the company, those challenges may vary in strength, intensity, and urgency.

However, in the end, regardless of what market or company you’re in, those challenges all boil down to these same 5 themes: 

  1. Increasing box complexity.
  2. Increasing variation in box quantity.
  3. Increasing unexpected orders.
  4. Increasing seasonal orders.
  5. Increasing cost pressure.

At IMPACK, we specialize in analyzing carton board and corrugated box manufacturers’ work methods and designing, manufacturing, and installing packaging equipment on and around folder-gluers. 

Let’s take a closer look at these 5 challenges and what they mean to you as a box manufacturer.

More importantly, we will cover exactly what steps you need to take to overcome those challenges. 

Challenge #1: Rapidly Growing Demand For Custom-Made Boxes

Today’s carton packaging market demands more and more personalization of boxes with shapes as diverse as they are varied.

This requires not only ever more flexible folder-gluers but also more flexible box manufacturers that are capable of quickly adapting to their customers’ needs in a market where everyone is aggressively competing for the same one goal: More customers. 

Custom-tailored boxes are becoming the norm. That’s the reality of today’s packaging industry.

And what this means to carton box manufacturers is being flexible and agile enough to produce innovative custom-made boxes efficiently while maintaining the lowest possible cost per box.  

That is, to get the biggest bang for your buck.

To do so, you must maximize your folder-gluer’s productivity.

How so?

Through optimizing your production capabilities.

One of the most effective ways to optimize your production capabilities is by integrating folder-gluer packaging equipment.

Why so?

Folder-gluer packaging equipment will allow you to reach higher packing speeds, reduce your manpower, and boost your folder-gluer’s productivity. 

And the way they allow you to do so is through partially or fully automating your packing process so that your folder-gluer can produce more —  in less time — and with less packing personnel. 

At IMPACK, we design and manufacture different types of folder gluer packaging equipment with varying levels of automation. This includes Manual, Semi-Automatic, Automatic, and Fully Automatic folder-gluer packers and peripherals.

???? Related: Manual Vs. Semi-Auto Vs. Auto Vs. Fully-Auto Folder-Gluer Packers: Which Is Best?

“But, what is a folder-gluer packer?!”

A packer is one of the 4 main folder-gluer packaging equipment that can be added to a folding-gluing line.

A packer is a system that is installed after the delivery belt of a folder-gluer and it allows you to automate your packing process. 

The level of automation a packer can offer always depends on the type of packer you choose and how the packer is configured. 

???? Related: What is a Folder-Gluer Packer and Do You Really Need One?

For example, IMPACK’s most sold machine of all our packaging equipment is the Ergosa packer. 

The Ergosa is a Semi-Automatic folder-gluer packer with the performance of an Automatic packer. Compact, highly flexible, and offering several packing modes, the Ergosa is a universal packer that combines flexibility with performance at a cost that won’t break the bank. 

Challenge #2: Increasing Demand for Orders without Minimum Quantities 

Many box manufacturers are increasingly offering their customers the option of placing orders without minimum quantities. 

Whether their customer requests 1 box, 10 boxes, or 30,000 boxes, they are capable of providing and quickly adapting.

Therefore, to ensure longevity in your industry as a box manufacturer, you must be flexible enough to offer the exact quantity of products that your customers are requesting. 

Failing to do so will result in your competitors stealing market share. 

Whether you’re producing small or large series, a single type of box or a varied production, easy or more complex products, IMPACK’s Ergosa packer allows you to run any box you shoot through your folder-gluer with short setup times and packing speeds that can exceed 100,000 boxes per hour. 

Curious to learn more about the Ergosa packer and the benefits it offers? Find out what the Ergosa packer is and how it can improve your packing process in this easy-to-read article!

Challenge #3: Last-Minute Orders are More and More Common

One of the most difficult challenges that box manufacturers face on an ongoing basis is last-minute orders.

It is one that box manufacturers have a love and hate relationship towards.

On one hand, last-minute orders mean more money and more business, but on the other hand, last-minute orders mean more stress and stricter deadlines for everyone. 

Last-minute orders are the orders that arrive at the end of the day — totally unannounced — and need to be managed first thing in the morning on the following day.

With those types of requests, your requirements remain the same and your customers’ expectations do not change: You must offer high-quality boxes that meet their needs, and on time.

To manage unexpected last-minute orders without risking losing those contracts, or your sanity, you need a high-performance machine that gives you the power of doing things a human can't: 

The power of producing more output with fewer packing personnel and faster output with shorter setup times.

And this high-performance machine is a folder-gluer packer.

IMPACK’s folder-gluer packers allow you to achieve higher packing speeds, greater output, less manpower, shorter setup times, and ultimately unleash your folder-gluer’s full potential.

Learn more about IMPACK’s packer options and the benefits they can offer to your packing process.

???? Related: What is a Folder-Gluer Packer and Do You Really Need One?

Challenge #4: Losing Contracts on Single & Seasonal Orders

Some products are manufactured regularly and repeatedly while others are small, one-off production runs. 

Take for instance seasonal products that are manufactured during Christmas, New Year’s, St. Patrick’s Day, or at special commercial events. Those products require frequent production changes to your folding-gluing line. 

And for those seasonal orders, it is often difficult to justify an investment in a folder-gluer packer since it would not likely yield an interesting ROI. 

Unfortunately, this causes many box manufacturers to drop contracts for seasonal orders simply because it just does not prove to be a profitable investment. 

And what happens to those customers?

They go to someone else; they go to a competitor of yours.

Sometimes a simple optimization to your folding-gluing line is all that you need.

Whether because of the specific style or format of those seasonal boxes, the orientation of the boxes being packed into the cases may vary and may require adjustments. 

For those seasonal orders, sometimes all it takes is integrating a box turner such as IMPACK’s IN3 box turner or the other box turners on the market.

The IN3 can be installed directly after your folder-gluer’s compression belt and before your packer. This offers you the capability to turn your boxes 90° to the left, 90° to the right, or straight through before packing them into the case.

The IN3 box turner is the most advanced version of the IN series. It turns all formats and types of boxes according to the desired orientation. Ideal with an automatic packer, the IN3 remains fixed regardless of the packing orientation chosen.

???? Related: What is a Box Turner and Do I Really Need One?

Video of the IN3 Box Turner in action:

Challenge #5: Maintaining Low production costs without Hurting Your Productivity

Everyone in the packaging industry is competing for lower production costs.

Lower costs mean greater price markups. 

Greater markups mean greater profits.

Greater profits mean business expansion.

Business expansion means happy bosses.

Happy bosses mean getting promoted at work.

And hey, what’s not to love about everyone being happy?!

But the billion-dollar question is: How can you lower the cost of your production while continuing to improve your productivity?

The answer is by,

  1. Reducing non-value-added activities
  2. Maximizing efficient machine utilization
  3. Reducing the number of staff per shift
  4. or beginning to automate your packing process.

The last point is the one that has the greatest impact on your cost and productivity.

Automating your packing process partially or fully offers a multitude of advantages. 

Typically, automation results in a reduction in the cost of your production which leads to an increase in your productivity and a higher net profit.

“But, should I go for semi-automation or full-automation?!”

Great question! The truth is, there are more solutions than just semi-automation and full-automation.

However, most folder-gluer packer manufacturers won’t tell you that because, naturally, they want you to opt for automatic or fully automatic packers that come with a much higher price tag.

???? Related: How Much Does a Folder-Gluer Packer Cost?

In fact, there are 4 categories of automation that most (if not all) packers on the market fit within: Manual packing, Semi-Automated packing, Automated packing, and Fully-Automated packing. 

And each of those 4 categories includes different types of folder-gluer packers that offer distinct features, benefits, and capabilities. 

The article “What’s the difference between Manual, Semi-Auto, Auto and Fully-Auto Folder-Gluer Packers” breaks down those 4 types of automation solutions and guides you step-by-step on how to choose the best packer for your production.

At IMPACK, we are committed to providing carton board and corrugated cardboard box manufacturers with innovative packaging equipment that can be easily integrated onto folder-gluers while taking up the least possible space.

This allows box manufacturers to minimize the cost of integration in a given space.

Each and every machine at IMPACK is designed with the company’s reality in mind. 

We understand that each company’s needs are unique and different. Backed with your data, our packaging equipment are custom-tailored to you, for you.

Got questions about IMPACK's packaging equipment and what they have to offer? ???? Get in touch with an IMPACK Expert and we’ll be happy to answer any questions you have and show you how you can become the top speed producer in your market!

Are You Stuck with One or More of the Above Challenges? 

As we saw, carton box manufacturers are confronted with growing pains that this complex industry is continuously bringing forth.

Hence, it is more important than ever for box manufacturers to stay abreast of changes in the packaging landscape and stand out from the competition.

Is your company currently stuck with one or more of those 5 challenges?

???? Get in touch with an IMPACK expert and we’ll show you what your options are to overcome those challenges!

Are you facing a challenge that’s outside of this list?

???? Contact us today and our team of engineers will offer you a FREE, no-obligation, productivity analysis to evaluate where exactly your company is facing bottlenecks and how you can solve them ✅.

It won’t hurt to have a quick discussion!

Recommended:

Top 5 Ways to Improve Your Folder-Gluer Productivity with Zero Investment

What is a Folder-Gluer Packer and Do You Really Need One?

Want more information on Full Automatic Carton Packing Line? Feel free to contact us.