Manufacturing

We supply corrugated packaging, folding cartons, rigid boxes, displays, inserts, foam, and mixed-material packs through our nationwide network of manufacturing partnerships.

Corrugated packaging moving through production equipment

Manufacturing equipment and production capabilities

Hercule Industrial sources production from qualified packaging plants across the United States. The equipment ranges below are available across that network. The quoted route depends on the package dimensions, material, print, quantity, finishing, location, and schedule. Maximum sizes and every finishing option are not available together on every production line.

Corrugated converting equipment

Production for mailers, shipping cases, displays, heavy-duty boxes, pallet boxes, and oversized multi-piece containers.

Corrugators and board: Access to corrugators up to 110 inches for N, F, and E microflute through common A, B, and C flutes, in single-wall, double-wall, and triple-wall constructions. Available grades include ECT and Mullen specifications, kraft and white liners, coated surfaces, moisture-resistant constructions, and heavy 500-pound-test BC double-wall.
Printer-slotters and flexo folder-gluers: Inline printing, slotting, folding, and gluing for regular slotted cases and related shipping-box formats. Available flexographic production ranges from one through seven colors, including inside print, two-sided work, GCMI and PMS matching, screening, trapping, and protective coatings.
Rotary and flatbed die cutting: Rotary die cutting is available to 115-inch widths for repeat production. Flatbed and platen equipment covers heavy board, shorter runs, precise openings, retail displays, inserts, and shapes that cannot run on a standard rotary line.
Large-format gluing, stitching, and joining: One-piece boxes can reach 100 by 212 inches, with blanks up to 102 by 440 inches. Specialty gluing to 150 inches, industrial stitchers, and equipment that joins as many as four pieces support pallet boxes and oversized cases.
Digital print and litho lamination: Direct digital sheets up to 63.5 by 118 inches support samples, short runs, and versioned work. Lithographic lamination up to 60 by 120 inches supports high-graphic boxes and displays.

Folding carton production equipment

Digital and offset presses: Plate-free digital production for printed comps, short runs, and multiple artwork versions, plus sheet-fed offset production up to seven colors for larger repeat carton orders. Available work includes inside print, process and spot colors, aqueous and UV coatings, and film lamination.
Die cutting and creasing: Flatbed and platen equipment for tuck cartons, lock bottoms, sleeves, trays, carriers, multipacks, handles, cutouts, perforations, and fitted paperboard inserts.
Folder-gluers and window patching: Straight-line and multi-point folding and gluing, hot-melt and cold-glue work, window-film application, and cartons prepared for hand packing or automatic cartoning.
Foil, embossing, and specialty finishing: Hot, cold, and digital foil; embossing and debossing; raised effects; soft-touch finishes; specialty papers; and registered decorative work for retail cartons and sleeves.

Rigid boxes and fitted interiors

Board cutting, forming, and wrapping: Production equipment for lid-and-base, drawer, hinged, shoulder-and-neck, slipcase, magnetic, and collapsible rigid boxes using heavy board and printed or specialty paper wraps.
Interior fabrication: Die-cut paperboard and corrugated platforms, partitions and cradles, fabricated polyurethane, polyethylene, and polystyrene foam, molded pulp, formed plastic, honeycomb, and mixed-material interiors.
Assembly and finishing: Insert placement, ribbon and magnet fitting, labels, printed literature, component grouping, and corrugated shipping cases can be included with the finished box.
Production quantities: Production-quality samples and suitable short runs can begin around 50 to 100 boxes. Conventional domestic setup-box production commonly begins around 500, with automated lines used for larger repeat programs.

Production examples

Heavy machined parts

For 50 to 60 pound cast-metal parts, the available range includes 500-pound-test BC double-wall full-overlap cases at a 175-case production quantity, subject to the final dimensions and packed load.

Cold-storage produce

A vented two-piece case and lid can combine stronger board, moisture-resistant adhesive, a white print surface, and a true fluorescent PMS ink drawdown approved on the actual liner before production.

Presentation kit

A printed rigid or corrugated presentation box can be supplied with fitted foam or paperboard, product cartons, literature, labels, assembly, and a separate corrugated shipping case.