Custom folding boxes are foldable boxes that are delivered flat and set up when required. They have a product-specific structure and can be produced in a wide variety of sizes and shapes. The number of cardboard types and types used is almost limitless.
WHAT ARE FOLDING BOXES USED FOR?
Folding boxes do not only differ in design – the material, shape and sizes are also subject to the content. They can be used for a variety of purposes. Folding boxes are suitable, for example, as product packaging, display packaging, gift box protection or functional storage and pharma box packaging.
In addition to its protective function, the folding box also serves as an advertising medium, guarantees product and brand identification, and ensures optimal storage and stacking of the goods.
WHAT MATERIAL ARE FOLDING BOXES MADE OF?
In the case of folding boxes, a rough distinction can be made between primary packaging made of cardboard and transport or shipping boxes made of corrugated cardboard.
In the primary custom folding boxes packaging area, stable, high-quality chromo cardboard is often used. This is ideal for offset and digital printing. A high-quality chromo sulfate cardboard is used for printed folding boxes that are to be presented as attractively as possible. Folding boxes made of natural cardboard or grass cardboard are also very popular. – Here you can choose from an extensive color palette.
WHICH DESIGN IS THE RIGHT ONE FOR FOLDING BOXES?
Folding boxes or folding boxes consist of a box body, also called a frame. This box body is connected to the base and cover flaps or a plug-in base / cover. Depending on the design, the folding boxes fulfill different functions:
Tuck-in flap with locking slits: attractive appearance, high functionality
Tuck-in flap with friction lock: attractive appearance, less stable
Tuck-in flap with locking tongue: more stability thanks to the locking tongue
Plug-in bottom: very robust, heavy filling
Automatic floor: a lot of stability, automatic erecting
The decisive factor is whether the custom printed display boxes in bulk are to be used vertically or horizontally. If it is lying down, the locks are positioned on the side and the bottom is not required. If it is up, the lid can close at the front or at the back.
Further information on the structure of folding boxes can be found down.
HOW ARE FOLDING BOXES MADE?
As soon as the material and design of the folding box have been determined, the construction begins in a CAD program. A cutting plotter uses the data created to produce a white sample, which is used to check the quality and pack size. If it meets the requirements, the developer creates the punching tool in a CAD program.
In the case of very small editions of the custom folding boxes, production with the punch is not worthwhile, as the die costs would make up too large a part of the production costs. Such supports are made with the help of the cutting plotter.
WHAT IS DIE-MAKING?
With the help of the CAD program, an automatic mesh is created in order to place several folding box blanks (also called panels) on a sheet. This saves material, time and money when punching.
The die maker saws the die-cut contours of the folding box into the carrier material with a laser or a scroll saw. Cross-glued special wood, steel sandwich panels or special plastic are suitable as carrier material. Then the cutting and creasing knives are inserted into the cut-out contours and the rubber coating is applied.
HOW ARE FOLDING BOXES PRINTED IN BULK?
Solid cardboard for folding boxes can be printed using offset, digital or gravure printing. Because of its high printing roller costs, gravure printing is only used for very long print runs. Offset printing is preferred for medium runs.
Digital printing, on the other hand, is ideal for small editions of folding boxes due to the short set-up time. Packaging can also be personalized and individualized.
The finished print sheet can be refined using various processes. These include, for example, dispersion varnish, UV varnish, foil lamination, hot foil stamping, and cold foil stamping or blind stamping. You can find more information on our Finishing page.
PUNCHING, STRIPPING AND DEPANELING IN THE MANUFACTURE OF FOLDING BOXES
After printing and finishing, the folding boxes are punched out. For this purpose, breakpoints are milled into the cutting lines of the die. The breakpoints prevent both the individual copies and the waste from falling through the machine when punching.
With automated punching, a gripper conveys the punched blanks to the stripping station. Special pens break out the waste and edge waste. The machine then separates the individual copies in the depaneling station and stacks them. This step is done by hand for small print runs.
HOW ARE FOLDING BOX BLANKS GLUED?
In the next step, the folder gluer glues and folds the folding box blanks. In this machine, the creases are pre-broken; the folding box is glued to the glue seam and then folded. A dispersion adhesive is used as the adhesive in most cases. After gluing, the folding boxes are scaled and transported on a press belt so that the glue sets.
ERECTING AND FILLING THE FINISHED BOX
Now the custom folding boxes only have to be filled with the desired product. Depending on the product and quantity, this is done by hand or in a packaging machine.
Birthday displays, anniversary presents, Christmas greetings or give-aways want to look good and be packaged in a stylish way. The right display packaging is of great importance because it contributes to the overall visual impression and can influence the perceived value of the display. So which display box would you like?
DISPLAY FOLDABLE BOXES FOR THE PARTY
In some regions of Germany it may seem strange, in parts of Bavaria it is a custom: For her 25th birthday, a single woman is given a large number of boxes, decorated her apartment with them or blocked her front door. The “box festival” is intended to allude to the colloquial expression “old box” – a custom that is of course not meant very seriously.
FIND THE RIGHT DISPLAY BOX
In general, custom display boxes can be designed very differently: Which type of box it is mainly depends on the content: Small content should be protected either by an inlay or by a further division inside the box. Sliding boxes, for example, can be used as packaging, but also hinged lid boxes and pillow boxes can be used to beautifully wrap displays.
Hinged lid boxes that open to the front can use the “treasure chest effect”: the lid is opened slowly and the display becomes visible, beautifully presented like a treasure. Large telescope boxes can contain larger-format displays, for example in A4 format.
WHEN IT COMES TO THE DISPLAY BOX, IT’S THE LOOK THAT COUNTS
The most important thing in foldable display packaging is the visual design. Whether colorfully printed, festive red or cautiously simple with simple but effective refinements: display boxes must match the recipient and represent the recipient.
Specifically, this means that if it is a company display, the colors of the company logo should definitely be reflected. For extraordinary occasions it can also be more extravagant – so not only the recipient is happy, the giver is also remembered longer and the box is more likely to be reused – maybe for the next box party?
Display box made of brown natural cardboard
Display box with a “natural look”: The refined top of the box makes the box look modern and classy at the same time.
CONCLUSION: DISPLAY BOXES
Our display box packaging is as individual as our customers. Whatever you have in mind, what you want to pack and what your budget is – please do not hesitate to contact us, we will advise you on your options!