Win on protection, cost, speed, and sustainability—without sacrificing brand. Below are proven structural tips we use at Influence Packaging to deliver right-sized, first-time-right solutions.
Right-Sizing
Stronger with Less
Faster Assembly
Mono-Material Options
1) Start with Internal Fit (L × W × H)
Design from the inside out. Measure internal dimensions at the opening and specify L × W × H. Add clearance for product, inserts, and handling tolerances (corrugated typically ±1/8″ / ±3 mm).
2) Choose the Right Material & Flute
| Material | Approx. Caliper* | Typical Uses |
|---|---|---|
| Folding Carton (SBS/CRB) | 0.014–0.024″ | Retail cartons, sleeves, small device packs |
| Corrugated E-flute | ~1/16″ (1.5–2 mm) | Mailer cartons, print-heavy e-com |
| Corrugated B-flute | ~1/8″ (3 mm) | RSC shippers, inserts, trays |
| Corrugated C-flute | ~5/32″ (4 mm) | Heavier products, stack strength |
| Double-Wall (BC) | ~1/4″ (6–7 mm) | Large/heavy items, pallet stacking |
*Calipers vary by mill/spec; confirm with your converter. Select ECT/edge-crush for stacking needs.
3) Engineer Closures for Speed
- RSC (Regular Slotted Carton): cost-effective shipper; tape close.
- FOL (Full Overlap): stronger top/bottom for heavy goods.
- Mailer w/ locking tabs: quick assembly; good for DTC unboxing.
- Auto-bottom / Crash-lock: fastest assembly on pack lines.
4) Score, Crease, and Allowances
- Mind the **score-to-cut** distances and **min panel widths** recommended by your plant—avoids tear-outs and crush.
- For folded wraps, allow for **material take-up** (board thickness) at tight turns.
- Call out **glue areas/no-print** zones on dielines to prevent adhesion issues.
5) Inserts that Do More with Less
- Switch foam to **corrugated/PB engineered inserts** or molded fiber where practical.
- Design for **multi-drop protection** (edges first) and easy pack sequence.
- Target **mono-material** (paper-only) systems to improve recyclability.
6) Cost Through Design
- Right-size to cut **DIM weight** and freight; 1–2″ reduction can be material.
- Optimize **sheet utilization** (common footprints, shared tooling).
- Standardize closures and board grades across SKUs for scale savings.
7) Test Early, Iterate Fast
- Proto & test: quick CAD cuts → pack trials → transit testing (e.g., ISTA 3A as appropriate).
- Track damage modes and revise insert contact points first.