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EVC11122

Crash-Lock Box with Built-In Insert Shelf

Available in a wide range of custom configurations & material selection.
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Product details

Top highlights

One-piece design eliminates separate inserts
Crash-lock base snaps open for fast assembly
Integrated shelf requires manual folding

About this product

The EVC11122 is a one-piece retail box designed to hold bottles, tubes, or cylindrical items securely without requiring a separate insert. The front panel features an extended section that folds inward to create a suspended horizontal shelf with custom cutouts, while the crash-lock bottom snaps open to speed up base assembly.

By integrating the insert into the main box, this design simplifies inventory and packing labor. Because the shelf requires a tight 180-degree fold, it performs well with thinner micro-flute boards and requires manual folding before the product can be loaded.

Common uses

Cosmetics and skincare tubes
Specialty beverage bottles
Retail kits with cylindrical components

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Retail Presentation for Bottles and Tubes

Cosmetics and skincare tubes

This box is built specifically for items that need to stand upright and stay separated. The suspended shelf prevents tubes from shifting or clashing during retail handling. Because the lid uses a secure tongue lock, the presentation remains clean and closed on the store shelf.

Specialty beverage and spirits bottles

For glass bottles that require lateral stabilization, the integrated shelf holds the neck or shoulder securely in place. The product rests directly on the crash-lock base, which handles the vertical weight while the shelf prevents tilting.

Multi-component retail kits

When packing a primary cylinder alongside smaller accessories, the shelf can be configured to hold the main item while leaving open space below or beside it for secondary components, keeping the presentation organized.

Fragile glass dropper vials

Small glass vials benefit from the suspended shelf, which keeps them separated and upright. The one-piece design ensures the protective shelf is always present and correctly sized for the specific vial diameter.

Streamlining Packing for Retail Kits

Manual kitting and assembly lines

For teams packing delicate retail goods by hand, managing separate die-cut inserts can slow down the line and complicate inventory. This one-piece approach ensures the insert is always attached. While the base auto-erects, packers will still need to manually fold the shelf down before loading the product.

Retail shelf display

The friction tuck lid features a small extending tongue that snaps into a receiver slit on the front wall. This provides a secure closure that resists accidental opening when handled by retail customers, maintaining a clean appearance.

Inventory consolidation

Procuring and storing a single box rather than a box and a separate insert reduces SKU count and simplifies ordering. This approach trades higher blank waste during manufacturing for a simpler bill of materials.

When to Consider a Separate Insert or Outer Shipper

High-volume automated loading

If the packing line uses automated loading equipment, the manual 180-degree fold required to form the internal shelf will likely cause a bottleneck. In fully automated setups, a standard crash-lock box paired with a machine-placed partition or a different retention strategy is usually a better fit.

Rough parcel and courier transit

This box is designed for retail presentation rather than rough transit. The friction tuck and tongue lock keep the lid closed on a store shelf, but they are not secure enough for courier networks. Parcel shipping will require an outer shipper or heavy taping.

Board Thickness, Print Placement, and Base Strength

Flute choice and the 180-degree fold

The integrated shelf relies on a panel that folds completely back on itself before extending horizontally. This 180-degree fold creates tension on the corrugated liner. Thinner micro-flutes, such as E-flute or F-flute, handle this fold cleanly. Thicker boards like B-flute are prone to cracking along the hinge and should be evaluated carefully.

Print placement on the drop panel

Because the shelf drops down from the top of the front wall, the inside surface of that extension becomes visible when the box is opened. If printing is only applied to the outside of the box, this dropped section will display the raw kraft or white board. Two-sided printing provides a uniform interior color.

Product weight and base strength

The internal shelf prevents the product from shifting side-to-side, but it does not bear the vertical weight of the item. The product rests directly on the crash-lock bottom, which must be strong enough to support the payload without bowing.

Production volume and folder-gluer setup

The crash-lock base requires a multi-point folder-gluer to pre-glue the bottom tabs. This setup process makes the box more practical for repeat programs or larger runs where the assembly time savings outweigh the initial manufacturing setup.

Adjusting the Shelf, Cutouts, and Closure

Shelf drop height

The depth of the shelf can be adjusted to sit exactly at the shoulder or neck of the bottle or tube. This ensures the product is held at the correct height to prevent vertical shifting.

Cutout sizing and shape

The circular cutouts are fully configurable in diameter and spacing to match specific products. The cutouts can also be changed to squares or custom profiles to hold jars or non-cylindrical items.

Tongue lock depth

The length of the locking tongue and the width of the receiver slit can be adjusted to change the friction fit. A deeper tongue provides a tighter lock for heavier retail handling.

Packing details

Blank sprawl and material efficiency

Integrating the shelf into the front panel makes the flat, unfolded box taller than a standard carton. This irregular footprint can reduce how efficiently the boxes nest on a corrugated sheet during manufacturing, which may increase the per-unit material cost compared to a simple box and a separate insert.

Additional notes

Manual shelf folding

Packers must fold the front panel extension 180 degrees inward and then 90 degrees horizontally to form the shelf. This manual step should be factored into packing time estimates.

FAQs

Does the internal shelf fold automatically when the box is opened?

No. While the crash-lock bottom snaps into place automatically when the box is squared, the internal shelf must be manually folded down and pushed into position before the product can be loaded.

Can this box be shipped through parcel networks without an outer carton?

Can the shelf hold products other than cylinders?

While the standard template uses circular cutouts for bottles and tubes, the shelf can be modified with different cutout shapes to hold square bottles, jars, or specific product profiles. The key requirement is that the product needs lateral stabilization.

Why is micro-flute recommended for this design?

The front panel must fold 180 degrees inward to position the shelf. Thicker corrugated boards resist this tight fold and can crack the printed liner. E-flute or F-flute provides the necessary foldability while maintaining enough rigidity for the shelf.

Is a one-piece box with a shelf cheaper than buying a box and a separate insert?

It depends on volume and packing labor costs. A one-piece design saves assembly time and simplifies inventory, but the extended front panel creates more waste during manufacturing. A prototype and quote can help clarify which approach is more practical for a specific run.

How does the top closure work?

The lid folds over from the back wall and features a tuck flap with a small extending tongue. This tongue snaps into a receiver slit on the front wall, providing a secure friction lock that resists popping open during retail handling.

Does the internal shelf support the weight of the product?

No. The internal shelf prevents the product from shifting side-to-side, but it does not bear the vertical weight of the item. The product rests directly on the crash-lock bottom, which must be strong enough to support the payload.

What happens if the inside of the box is unprinted?