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FEFCO 0227

Full-Overlap Bottom File Box

  • Available in a wide range of custom configurations & material selection.
  • Order 1 sample. Or order 100K+ units. Or anything in between.
  • Affordable delivery across North America.
  • Design support, warehousing, testing, assembly available.
  • Widest machinery capability in America via 30+ specialist partner plants.
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Product details

Top highlights

  • Full-width outer flaps overlap across the top and bottom
  • Semicircular edge thumb notches help separate two closure flaps
  • No hand holes or built-in lifting handles

About this product

The full-overlap bottom file box uses full-width outer flaps on both closing ends, creating overlapping corrugated layers across the top and bottom. Small semicircular thumb notches appear at the edges of two closure flaps to help separate or open the flaps.

The notches are edge cutouts, not hand holes through the side walls, so this style should not be treated as a handled moving box. Board grade and closure method should be selected from the packed product, box dimensions, and handling conditions.

Common uses

  • Archival document storage
  • Heavy mechanical parts transit
  • Household moving and relocation
  • Industrial kitting

Get a quote

Share what you know. We'll take it from there. Or email us at info@herculeindustrial.com

Best Price Guarantee

Already have a packaging quote? Let us beat it.

Send us the quote you have. We will beat it for the same specifications, quantity, and delivery requirements.

Upload a competing quote

Free quote review. No obligation.

30+specialist partner plants

We supply through the plant best suited to your price, material, production, and delivery requirements.

Why we can beat a lower quote

30+ plants give us more ways to lower the price.

Each plant has different machinery, material costs, order minimums, and freight rates. Our buying volume helps us secure better pricing. We then quote through the plant that gives you the lowest total price for your requirements.

Send us your current quote. Watch us beat it.

Attach it to the quote form or email it to us. We'll review it free and send you our price.

Upload a competing quoteinfo@herculeindustrial.com
Best Price Guarantee terms

To qualify, send a written supplier quote dated within the past 30 days and addressed to your company. It must cover the same dimensions, construction, material, print, finish, quantity, tooling, freight, delivery date, and delivery location. The guarantee does not cover taxes, expired quotes, liquidation or clearance sales, or obvious pricing errors.

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Heavy-duty transit and archival storage

Archival document and file storage

Dense stacks of paper create severe point loads that can bow or break a standard box floor. The double-thick overlapping base supports the weight, while the hand holes allow staff to pull boxes from shelves and carry them safely.

Heavy mechanical parts transit

When shipping dense metal components, the fully overlapping flaps provide critical puncture resistance against sharp edges. The handles make it easier for warehouse teams to maneuver the loaded box onto pallets or workbenches.

Household moving and relocation

For mixed, heavy household goods, this structure offers the burst strength needed for unpredictable loads. The ergonomic grip reduces fatigue during repeated manual lifting.

Industrial kitting and sub-assembly transfer

Plants moving heavy fasteners, brackets, or sub-assemblies between stations rely on the reinforced floor to prevent spills. The hand holes speed up manual transfer between work zones.

Logistics, records management, and industrial kitting

Records management and legal archiving

Facilities storing thousands of document boxes need containers that handle years of handling without the bottom giving out. The double-thick base ensures long-term integrity, even when boxes are repeatedly shifted.

Industrial manufacturing and assembly

Manufacturing environments moving heavy components rely on packaging that withstands rough handling. The fully overlapping base prevents heavy parts from breaking through during transit.

Commercial relocation services

Moving companies handling heavy, unpredictable loads benefit from the burst strength of the double-thick base and the ergonomic advantage of integrated hand holes.

When to evaluate standard or lid-based alternatives

When material efficiency is the primary goal

If the payload is light to medium weight, the fully overlapping flaps consume unnecessary board. A standard Regular Slotted Container (FEFCO 0201) uses less material and is more economical for general shipping.

When frequent access is required

Because the top flaps must be taped or stapled shut, reopening the box requires cutting the seal. If the contents need to be accessed repeatedly, an Archive Box with a removable friction lid (FEFCO 0225) is a more practical choice.

When automated packing lines are used

The massive, double-thick flaps can be difficult for automated case erectors to fold and seal. If the packing process is fully automated, a standard slotted box is usually required.

Close variants and lookalike dielines

The closest library neighbors include 0710, 0711, 0225. Use this as a variant check if a buyer brings an old code, sample, or dieline that looks close. The deciding details are usually the lock, slot, closure, wall build, part count, or fold sequence.

Board strength, closure methods, and production routing

Board grade and handle tear-out risk

The hand holes carry the entire weight of the box during lifting. While single-wall board may suffice for lighter files, heavy industrial loads often require double-wall corrugated to prevent the board above the handles from tearing out.

Tape versus staple closure

The fully overlapping flaps create a stiff, double-thick barrier that resists folding, especially in heavy board grades. End-users must secure these flaps firmly with heavy-duty packaging tape or industrial staples to lock the geometry in place.

Production route and die-cutting requirements

Unlike a basic shipping box, the die-cut hand holes mean this package cannot be produced on a simple straight-knife slotter. It requires a rotary or flatbed die-cutter, which affects production routing and minimum viable run sizes.

Blank sprawl and machine limits

Because the outer flaps extend across the entire width of the box, the flattened blank is exceptionally tall. For very wide boxes, this massive footprint can exceed the physical limits of standard converting equipment, requiring specialized large-format production.

Adjusting handle profiles and flap sequences

Handle shape and placement

The thumb cuts can be modified from a squared profile to a rounded radius for better ergonomics. Their vertical placement can also be adjusted, though positioning them too high reduces the amount of board supporting the lifted weight.

Flap layout sequence

The sequence of the wall panels can be shifted (e.g., W-L-W-L instead of L-W-L-W) to help the wide blank fit through the folder-gluer more efficiently, without changing the final assembled shape.

Removing hand holes for straight-knife production

If manual lifting is not required, removing the hand holes converts the design into a standard Full Overlap Slotted Box (FEFCO 0203), which can be produced without die-cutting equipment.

Board and packing details

Folding resistance with heavy board

When using double-wall corrugated for maximum strength, the large overlapping flaps become stiff and require more manual effort to fold squarely at the packing bench.

Layout variants for production efficiency

W-L-W-L layout sequence (0227a)

Alters the sequence of the wall panels to manage the massive blank size, helping it fit through the folder-gluer more efficiently.

Parameter variations for heavy board (0227_1)

Adjusts slot depths and flap clearances to prevent the fully overlapping flaps from binding when using thick double-wall board.

Additional notes

Folding resistance with heavy board

When using double-wall corrugated for maximum strength, the large overlapping flaps become stiff and require more manual effort to fold squarely at the packing bench.

Related heavy-duty and archival boxes

FAQs

Product fit and handling

Do the hand holes weaken the box?

Yes, cutting holes into the side panels removes vertical fluting, which slightly reduces the overall top-to-bottom stacking strength. The board above the handles also becomes a stress point during lifting, which is why heavy loads often require double-wall board.

Closure and packing

Can this box be assembled without tape?

No. While the side seam is glued at the factory, the top and bottom flaps have no native locks. They must be secured with strong tape or staples to hold the heavy overlapping layers in place.

Production and material

Why does this style consume more material than a standard shipping box?

The fully overlapping flaps effectively double the amount of corrugated board used on the top and bottom faces. The flattened blank must be much taller to accommodate these extended flaps.

Can I order this in very large dimensions?

It depends on the factory's equipment. Because the flaps equal the full width of the box, the flattened blank becomes extremely large. Very wide boxes may exceed the size limits of standard converting machines.

Board and finish

Is double-wall board always required?

Not always. High-quality single-wall board can handle standard paper files. However, for dense metal parts or heavy household goods, double-wall board is recommended to prevent the handles from tearing and the walls from buckling.

Route and shipping

Is this box suitable for parcel courier networks?

Yes, but only if the outer flaps are heavily taped or strapped. The large overlapping flaps can catch on automated sorting conveyors if they are not sealed flat against the box.

Product fit and handling

How does the fully overlapping base improve drop resistance?

By extending the outer flaps across the entire width of the box, it creates a continuous, double-thick floor. This prevents the center seam from splitting open under heavy point loads, which is a common failure point in standard slotted boxes.

Adjustments and options

What happens if the hand holes are placed too high?

Positioning the hand holes too close to the top edge reduces the amount of corrugated board supporting the lifted weight. This increases the risk of the handles tearing out when the box is fully loaded.