Automated Cartoning and Manual Packing
Automated cartoning lines
The tapered corners on the major flaps are designed to clear machine guides during rapid folding. This reduces the risk of flap collisions compared to straight-cut flaps.
Manual packing stations
Because the side seam is pre-glued by the converter, packers simply open the flat tube, fold the bottom flaps, and seal the ends. The tapered flaps fold smoothly by hand without binding at the corners.
Inner product sleeves
When used as an internal protective layer, the tube can be slipped over a product and sealed at the ends, keeping the primary item secure before it goes into a master carton.
Mixed-product fulfillment
Operations running various product sizes through automated closers benefit from the predictable folding behavior of the tapered flaps, helping maintain steady throughput.
Fulfillment Centers and Contract Packagers
Contract packaging and fulfillment
Facilities handling diverse product runs appreciate the predictable machine clearance provided by the tapered flaps.
High-speed manufacturing
Environments where line jams cause downtime often prefer tapered flaps to ensure smooth automated closure.
E-commerce distribution
Operations prioritizing fast manual erection and taping over complex folding sequences can use the pre-glued side seam for quick assembly.
Straight-Flap Alternatives for Simpler Production
Straight-flap boxes for simpler production
If the package will be erected entirely by hand and machine clearance is not a concern, a standard Regular Slotted Container (FEFCO 0201) may be a practical choice. Straight flaps can often be produced without shaped die-cutting.
Full overlap tubes for heavy loads
If the major flaps need to completely overlap for extra strength or specific gluing requirements, the EVC11903 template is worth comparing.
Flap Overlap, Sealing Method, and Production Route
Flap meeting and central gap
By default, the major flaps on this template do not meet in the center, leaving a gap. If the package needs to be fully enclosed, the flap length must be adjusted to meet, or the gap must be bridged by wide tape or an inner liner.
Sealing method and flap length
The intended closure method changes the required flap dimensions. Adhesive sealing requires sufficient overlap or contact area, while a taped closure typically requires the flaps to meet in the center.
Production routing
While straight-flap boxes are often produced on straight-line slotting equipment, the angled cuts required for the tapered flaps often mean this package must be routed through a shaped die-cutting process before gluing.
Board thickness and slot width
If moving to a thicker corrugated flute, the slots separating the flaps must be widened to prevent the board from binding when folded.
Adjusting Tapers and Flap Clearances
Modifying the flap taper
The angle and depth of the chamfer on the major flaps can be adjusted to match the specific clearances required by your packing equipment.
Slot width for heavier board
The slots separating the flaps can be widened to accommodate thicker corrugated flutes, ensuring the flaps can still fold 90 degrees without binding.
Adjusting flap overlap
The flap height parameter can be changed to create a full meeting closure or an overlapping seal, depending on the chosen sealing method.
Packing details
Production routing and die-cutting
The requirement for tapered flaps usually shifts production from straight-line slotters to shaped die-cutting. This ensures the tapers are cut cleanly for reliable machine folding.
Additional notes
Shaped die-cutting versus straight-line slotting
The requirement for tapered flaps usually shifts production from straight-line slotters to shaped die-cutting. This ensures the tapers are cut cleanly for reliable machine folding.
Related Corrugated Shippers
FAQs
Does this box fully enclose the product?
In its default template state, the top and bottom flaps leave a central gap. To fully enclose the product, the flap dimensions must be adjusted so they meet in the middle, or the gap must be sealed with tape.
Can this be manufactured on straight-line slotting equipment?
Usually not. The angled tapers on the major flaps typically require a shaped die-cutting process, which provides precise flap clearances but differs from the simpler slotting used for basic straight-flap boxes.
Why are the major flaps tapered?
The trapezoidal shape prevents the corners of the flaps from catching on machine guides or each other when being folded rapidly on an automated cartoning line.
Can I use a heavy board grade for this tube?
Yes, but the slot widths between the flaps and the crease allowances must be carefully adjusted to accommodate the extra thickness, ensuring the flaps can still fold 90 degrees without binding.
How is this package delivered?
It is delivered flat, or knocked down, with the side seam already glued. The packer or machine simply pushes the opposite corners to open it into a rectangular tube.
What are the common ways to seal the ends?
The best method depends on your packing line. Automated lines typically use adhesive applied to the flaps, while manual stations often use tape. The flap dimensions should be tailored to your chosen method.
Can the flap gap be removed?
Yes. The flap height can be adjusted before production so that the major flaps meet exactly in the center, creating a fully closed surface for taping.
Is this suitable for parcel shipping?
It can be used for parcel shipping only if the flaps are adjusted to meet in the center or if the gap is fully sealed with appropriate packaging tape.
