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ECMA A61.11.01.03

Crash-Lock Carton with Overlapping Top Flaps

  • 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 base snaps open for rapid manual or automated loading
  • Overlapping top flaps create a flat surface for tape or security labels
  • Delivered flat (KDF) to save warehouse space before use

About this product

This folding carton combines a fast-erecting auto-bottom base with a flat, overlapping top closure. Delivered flat with the bottom pre-glued, it snaps open instantly when the edges are squeezed, eliminating the need to manually fold or tape the floor.

Because the top flaps overlap rather than tucking in, this design needs an external seal, such as tape, a tamper-evident label, or adhesive, to stay closed. It is a practical choice for high-volume packing lines equipped to seal the top quickly.

Common uses

  • High-volume contract packaging where labor time is the main cost driver.
  • Retail products requiring a tamper-evident top seal.
  • Automated cartoning lines equipped for top-gluing.

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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Closed-bottom packing jobs

High-volume fulfillment

The pop-open bottom reduces assembly time per unit, making it efficient for fast-paced packing lines where labor speed is the priority.

Tamper-evident retail packaging

The flat overlapping top provides a clean, uninterrupted surface for security seals or branded labels that must be broken to open the box.

Automated cartoning

The auto-bottom geometry works well with automated erecting machinery, provided the packing line can also fold and seal the top flaps.

Lightweight component kitting

Fast base assembly helps organize parts quickly, and the flat top allows for easy application of routing or inventory labels.

Product categories and channels

Contract packaging (Co-packing)

When labor time dictates the packing rhythm, the crash-lock bottom speeds up throughput compared to standard straight-line cartons that require manual floor assembly.

Health and beauty

Often used for lightweight bottles or jars where a top security label is required for retail shelves, and the flat top flap provides the necessary surface area.

Pharmaceutical and supplement packing

The flat top supports clear labeling and security seals, which are standard requirements for these product categories.

When to consider a different carton style

When you want a friction-locked top

If you prefer a top that closes securely without tape or glue, compare the A61.20.01.03. It uses the same fast-erecting bottom but features a tuck-in top flap.

When running short trials

If you are running a short trial and want to avoid the production routing required for crash-lock gluing, a standard 1-2-3 bottom or straight-line carton may be easier to source for small volumes.

Fit, board, and route choices

Top sealing method

Decide whether the top will be sealed with tape, a branded label, or adhesive. The top flaps do not have friction locks and will pop open if left unsealed.

Board thickness and pop-open tension

The crash-lock mechanism relies on precise folding. Thicker boards require careful adjustment to the crease offsets to ensure the bottom snaps open without binding.

Product weight

While the interlocking bottom is secure for standard retail items, very dense or heavy products may cause the floor to bow. Weight distribution should be checked during sampling.

Packing line layout

Verify that the packing line has the space and equipment to apply tape or labels immediately after loading, as the top flaps will not stay closed on their own.

Template adjustments

Flap height adjustments

The reduced inner flaps can be adjusted in height to change the rigidity of the top closure or to accommodate specific label placements.

Window cutouts

A display window can be added to the main panels, provided it stays clear of the complex diagonal creases required for the auto-bottom.

Dust flap shaping

The inner dust flaps can be modified with angled cuts to clear specific product shapes or internal inserts during loading.

Board and packing details

Master carton planning

Like most folding cartons, this design is not meant for raw parcel shipping and should be packed into a corrugated master shipper for transit.

Storage and delivery

Cartons arrive knocked-down flat. The pre-glued bottom adds slight thickness to the flat blank, which should be factored into pallet density planning.

Additional notes

Crash-lock setup considerations

The auto-bottom mechanism requires specific folding equipment during manufacturing. This makes the initial production run slightly more complex than a simple glued sleeve, but pays off in packing speed.

Related packaging to compare

FAQs

Closure and Sealing

Does the top of this carton lock on its own?

No. The top flaps overlap and rest flat. They must be secured with tape, a label, or adhesive to keep the carton closed.

Production and Board Choice

Can I use corrugated board for this design?

It is primarily designed for paperboard. Using thicker corrugated board requires adjustments to the bottom creases so the pop-open action does not bind during erection.

Why choose this over a standard straight-line box?

The pre-glued bottom eliminates the need for a packer to manually fold and tape the floor, speeding up the packing process for high-volume runs.

Shipping and Handling

Is this box safe for heavy items?

The crash-lock bottom supports standard retail weights well, but very dense point loads can cause the floor to sag. Heavy industrial parts usually require a different base style or a corrugated shipper.

Can I ship this directly in the mail?

No, this is a primary folding carton. It should be packed inside a corrugated outer box for courier or parcel networks.

Closure and Sealing

Can this be used with automated packing lines?

Yes, the crash-lock bottom is compatible with automated erectors, as long as your line can handle the top-sealing step.

Shipping and Handling

How are these cartons delivered?

They arrive knocked-down flat with the base pre-glued, ready to be popped open on the packing line.

Closure and Sealing

Can I use a tuck-in top instead?

Yes, if you want to avoid taping or labeling the top, a related style like the A61.20.01.03 offers a friction-fit tuck closure.