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ECMA A60.11.00.03

Crash-Lock Carton with Overlapping Top Flap

  • 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

  • Crash-lock bottom snaps open for fast manual packing
  • Top flap relies on a label, tape, or glue dot to stay closed
  • Delivered flat with side and bottom seams pre-glued

About this product

This folding carton combines a fast-erecting auto-bottom with a simple overlapping top flap. It is delivered flat and pops open, creating a rigid floor that supports product weight without bottom tape.

Because the top flap does not have a friction tuck tab, it rests flat across the opening and relies on a secondary seal, such as a tamper-evident label, tape, or glue dot, to stay closed. This makes it a strong choice for retail packaging where a visible seal is part of the design.

Common uses

  • Retail goods needing a tamper-evident seal
  • Cosmetics and pharmaceuticals
  • Fast manual fulfillment lines

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.

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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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Retail and Fast-Fulfillment Packing

Tamper-evident retail goods

When the product relies on a visible security seal, the plain top flap provides a clean surface for a branded or destructible label. The fast bottom keeps packing lines moving.

Light to medium-weight consumer products

The interlocked floor holds items securely without bottom tape, making it suitable for cosmetics, pharmaceuticals, and small electronics.

High-volume manual packing

For operations where hand assembly speed is the primary bottleneck, the auto-bottom base removes the need to fold and interlock individual bottom flaps.

Subscription box inner cartons

When used inside a larger corrugated mailer, this carton provides a clean presentation and a simple unboxing experience once the top label is broken.

Where the Overlapping Top Makes Sense

Manual packing lines

The auto-bottom design eliminates the need to fold and interlock bottom flaps by hand, reducing assembly time per unit compared to simpler bases.

Automated cartoning

While often erected by hand, this package can run on automated filling equipment, provided the magazine and erecting machinery are set up to handle the bulk of the pre-glued crash-lock folds.

Retail shelf display

The flat top panel offers an uninterrupted surface for branding or regulatory information, while the sealed closure reassures retail buyers that the product is unopened.

When to Consider a Tuck Top or Snap-Lock Base

If you want a top that stays closed on its own

Look at the A60.20.00.01. It uses the same fast bottom but adds a friction tuck tab to the top flap, allowing the carton to close securely without tape or labels.

If avoiding factory gluing is preferred over packing speed

Look at the A55.10.01.03. It uses a snap-lock bottom, which takes longer to fold by hand but avoids the pre-glued crash-lock base.

Sealing, Board, and Production Choices

Top sealing method

Decide how the top flap will be secured. If using a label, ensure the board's surface finish or coating will accept the adhesive reliably.

Production volume and setup

The crash-lock bottom relies on a multi-point folder-gluer. This setup is useful for repeat runs but involves more initial preparation time than a simple straight-line carton.

Board caliper and product weight

While the bottom is secure, the overall rigidity depends on the board thickness. Heavy items may cause the side panels to bow if the board is too thin.

Flat delivery profile

Because the bottom flaps are folded inward and glued, the flat carton has uneven thickness. This affects how many blanks fit in a shipping case and how they feed into automated magazines.

Adjusting the Flap and Base Dimensions

Top flap coverage

The main top flap can be extended or reduced depending on how much overlap is needed for the sealing label.

Dust flap depth

The three minor flaps that sit under the main cover can be adjusted to prevent product from slipping out of the corners.

Crash-lock base proportions

The interlocking bottom flaps scale with the width and length of the carton, but extreme aspect ratios may need adjustments to ensure the base folds flat properly.

Board and packing details

Grain direction

For good stacking strength and to prevent the main panels from bulging, the paperboard grain should run horizontally around the carton.

Additional notes

Label placement and surface finish

If you plan to seal the top flap with a tamper-evident label, ensure the carton's varnish or coating does not resist the label's adhesive.

Related Folding Cartons

A60.20.00.01: Tuck-top closure with crash-lock bottom

A strong alternative when the top needs to stay closed without tape or labels.

FAQs

Closure and Sealing

Will the top flap stay closed without tape?

No. Because this style lacks a tuck tab, the top flap simply rests over the opening. It relies on a label, tape, or a glue dot to remain secure during handling.

Assembly and Packing

How much faster is a crash-lock bottom than a standard folded bottom?

A crash-lock bottom pops into a rigid floor in one motion when the flat carton is squeezed open. This is faster than manually folding and interlocking a snap-lock base, making it useful for high-volume hand packing.

Production and Tooling

Does the crash-lock bottom affect the manufacturing process?

Yes. It relies on a 3-point gluing process at the factory, involving one side seam and two bottom points. This is standard for folding cartons but involves more setup than a simple side-seam glued box.

Shipping and Route

Can this carton be shipped through parcel networks on its own?

Generally, no. Like most paperboard folding cartons, it is designed as primary packaging and usually relies on a corrugated outer shipper for parcel networks.

Materials and Finish

Can this be made from corrugated board?

It is typically made from folding boxboard or solid bleached sulfate. While micro-flute corrugated can sometimes be used, the complex folds of the crash-lock bottom can become too bulky and jam standard folding equipment.

Inserts and Fit

Can internal dividers be added?

Yes, separate paperboard inserts or partitions can be dropped in after the carton is popped open to separate components or hold a product in place.

Samples and Prototyping

Can I get a prototype of this carton before a full production run?

Yes. Prototypes are often cut on a digital table and glued by hand to verify product fit, bottom snap action, and label placement.

Closure and Sealing

What kind of label is common for the top flap?

A tamper-evident or destructible label is often used. The label adhesive should be compatible with the carton's surface coating or varnish to ensure a reliable seal.