Folding cartons

Folding carton design

A folding carton is the printed paperboard box you see on shop shelves: cosmetics, supplements, tea, candles, small electronics. It ships flat, folds into shape, and is printed with much finer detail than a corrugated mailer.

Packaroo lets you design a straight tuck end carton on its real dieline, fold it in 3D, and export a spec pack your carton printer can quote from.

The straight tuck end carton

Packaroo draws the straight tuck end carton (ECMA A20): both tuck flaps hinge from the back panel and close from the same side, so the front panel stays clean with no flap edge showing. Dust flaps fold in under the tucks, and a glue flap joins the carton down one side.

It suits cosmetics, supplements, tea, candles and other light retail products, and it is the style most people picture when they think of a shelf box.

Sizes

Start from one of four stock sizes, all inside dimensions: Small 60 x 40 x 100 mm, Medium 90 x 60 x 140 mm, Large 130 x 80 x 200 mm and Tall 45 x 30 x 180 mm. Or type your own length, width and height and the dieline and 3D preview update as you go. See the carton template.

Folding carton vs mailer box

Folding cartons are single-layer paperboard (typically 250 to 450 gsm, or around 0.4 to 0.6 mm), printed with fine detail and finishes like foil and spot gloss, and sold on shelf. Mailer boxes are corrugated, with a fluted middle layer, much stronger for shipping, and printed more simply.

If the box goes in the post on its own, use a mailer box. If it sits on a shelf or inside a shipper, use a folding carton.

Board and finishes

Common boards are folding boxboard (FBB) for cosmetics and food, solid bleached board (SBS) for the cleanest print, and recycled grey-back board for lower cost. In Packaroo you choose a paperboard from 300 to 450 gsm.

Cartons take gold foil, silver foil and spot gloss in Packaroo, each on its own layer and exported as its own plate. More on print finishes.

Frequently asked questions

Which carton style does Packaroo make?

The straight tuck end, in four stock sizes or your own inside dimensions, on paperboard from 300 to 450 gsm.

What is the minimum order for folding cartons?

It depends on the printer; digital printers can do a few hundred, offset printers usually start in the low thousands. Use Get a quote in Packaroo, or send your spec pack to the printers you are comparing.

Is a folding carton strong enough to post?

Not on its own. Put it inside a mailer or shipping box.

Which size should I choose?

Measure the product and add 1 to 2 mm each way for a snug fit, more if there is an insert.

See it on your own pack.

Start on the free plan: design on a real dieline, preview it in 3D, and pay when you export.