Printed folding cartons and carton boxes
Printed Folding Cartons
Folding cartons are printed boxes cut and creased from a single sheet of board, glued at one seam and delivered flat for you to fold up at packing. We make printed folding cartons to your product's dimensions in folding boxboard, SBS or kraft board, in tuck end, crash-lock, snap lock, seal end, sleeve, pillow, gable and window styles. Send your dimensions and quantity for a quotation.
- Construction
- Printed paperboard, delivered flat
- Board
- FBB, SBS or kraft, typically 300–400 GSM
- Styles
- Tuck end, crash-lock, sleeve, pillow, window
- Minimum order
- 50 boxes
Overview
The most economical fully printed box
A folding carton is specified by three decisions: the structure (how it opens, closes and holds the product), the board (how stiff and heavy it feels) and the print and finish (how it looks on the shelf). Get the structure right first. A carton that pops open, sags or lets the product rattle undoes any amount of good print.
The carton starts as a flat printed sheet. A cutting forme cuts the outline and creases the fold lines, the side seam is glued, and the cartons are delivered flat in boxes. At packing they square up, the base closes, the product goes in and the top tucks or locks shut. Because they are delivered flat, cartons take a fraction of the storage space of rigid boxes.
Folding boxes, paper boxes and die-cut boxes are all names for the same family. Cube boxes and pyramid boxes are shape variations of it: a cube is a carton with equal sides, usually a tuck end or crash-lock construction, and a pyramid is a die-cut shape that folds to a point, used for favours and confectionery. Almost any flat-sided shape can be drawn as a carton dieline, provided it folds from one sheet.
Cartons are primary retail packaging, not transit boxes. They protect the product on the shelf and in the hand, but for posting direct to customers they normally travel inside a mailer box or corrugated outer. If a single box must do both jobs, a printed E flute mailer is often the better choice.
Structures
Folding carton styles
The closure you choose sets how fast the carton packs, how much weight the base holds and how the customer opens it.
Box style
Straight tuck end boxes
Top and bottom flaps tuck in from the same side. A clean front panel and the usual choice for cosmetics and gift cartons.
Read the style guideBox style
Reverse tuck end boxes
Top and bottom flaps tuck from opposite sides. Economical on board and quick to pack for light products.
Read the style guideBox style
Crash-lock (auto lock) bottom boxes
The base is pre-glued and locks itself as the carton is squared up. Faster to pack and stronger for jars and bottles.
Read the style guideBox style
Snap lock bottom boxes
A 1-2-3 base folded by hand. Holds more weight than a tuck base without the extra gluing of a crash-lock.
Read the style guideBox style
Seal end boxes
Flaps are glued shut at both ends. Used for food and products packed on automated lines.
Read the style guideBox style
Sleeve boxes
An open-ended printed sleeve over a tray or the product itself. A simple way to brand a range.
Read the style guideBox style
Pillow boxes
Curved ends that close by pressing inwards. For accessories, small gifts and soft goods.
Read the style guideBox style
Gable and handle boxes
A carton with a built-in carry handle. Popular for bakery, hampers and event gifting.
Read the style guideBox style
Window boxes
A die-cut window, open or patched with clear film, that shows the product through the carton.
Read the style guide
Sizing
Sizing a folding carton
Send the product's length, width and height, or the diameter and height for round items, in millimetres. We size the carton with a small clearance so the product slides in and out without moving inside the box. Too tight and the carton bulges and scuffs; too loose and the product rattles and the carton looks under-filled.
Carton dimensions are quoted as length × width × depth, where length and width are the opening and depth is the distance between the two ends. Getting that order right matters, because it decides which panel faces the customer and where the tucks sit. If you are unsure, send a photo of the product and tell us which face should be the front.
Where a product comes in several sizes, we keep the same style and specification and change only the dimensions, so the range stays consistent on the shelf through every reprint.
Materials & finishing
Carton boards
Most folding cartons use 300–400 GSM board; larger or heavier cartons use heavier grades. Calliper in microns varies by board type: folding boxboard is bulkier than SBS at the same weight. Figures are typical and vary by mill, and we confirm the board on your quotation.
| Specification | Typical range | Notes |
|---|---|---|
| Folding boxboard (FBB) | Typically 250–400 GSM | A layered board with a bright coated top and a bulky middle. Stiff for its weight and the workhorse of cosmetic, food and retail cartons. |
| Solid bleached board (SBS) | Typically 250–400 GSM | Bleached fibre all the way through, so cut edges and the inside are clean white. Chosen for premium cartons and fine print. |
| Kraft board | Typically 300–400 GSM | Unbleached brown board with a natural look. Suits one- or two-colour print and brands with a natural or artisan positioning. |
| Recycled carton board | Typically 300–450 GSM | A white-coated board made mainly from recycled fibre with a grey back. Economical for secondary and value cartons. |
| Heavier boards | 450 GSM and above | Used for large cartons, heavier contents or where a firmer feel is part of the product's positioning. |
Finishes
- Matt lamination
- Gloss lamination
- Soft-touch lamination
- Foil blocking
- Embossing and debossing
- Spot UV
- Window patching
Options
Options you can specify
Printing
- Full-colour CMYK
- Pantone spot colours for brand colours
- Inside printing
- One- or two-colour print on kraft
Structure
- Tuck end, crash-lock, snap lock or seal end
- Hanging tabs with a euro slot or round hole
- Die-cut windows
- Tear strips and perforated openings
Inserts
- Card platforms and cradles
- Dividers for multi-packs
- Neck holders for bottles
- Corrugated inserts for heavier items
Finishing
- Lamination: matt, gloss or soft-touch
- Foil blocking and embossing on logos
- Spot UV on a matt surface
- Clear window patching
Applications
Where folding cartons are used
Cosmetics and skincare
A family of cartons for serums, creams and lip products, sharing one print and finish specification across sizes.
Health and supplements
Tuck end or crash-lock cartons around bottles and jars, with space for directions and product information.
Food and confectionery
Cartons for chocolate, biscuits and baked goods, with the board and any coating chosen for how the food is packed.
Candles
Crash-lock or tuck end cartons with a card insert that keeps the jar from moving.
Cube and pyramid boxes
Shape variations for favours, confectionery and small gifts, cut from one sheet like any other carton.
Tea and coffee
Printed cartons for tea bags, pods and pouches, often with a window or hanging tab.
Small electronics and accessories
Heavier-board cartons with a card cradle for chargers, cables and small devices.
Compare
Tuck end or crash-lock bottom?
| Feature | Tuck end carton | Crash-lock bottom carton |
|---|---|---|
| Base | Tuck flap, folded by hand | Pre-glued base that locks as the carton squares up |
| Packing speed | Slower; each base is tucked | Faster; the base forms itself |
| Weight it holds | Light products | Heavier products such as jars and bottles |
| Board and gluing | Less board, one glued seam | More board and extra glue points |
| Typical use | Cosmetics, lip products, small gifts | Candles, supplements, bottles, food |
How to choose
How to choose your folding carton
Choose the closure for the weight
A tuck end suits light products. For jars, bottles and anything heavy, a crash-lock or snap lock base stops the bottom opening under load.
Pick the lightest board that works
Heavier board costs more and adds weight without improving a carton that already holds its shape. We recommend the board against the product and the finish you want.
Decide which panel is the front
The front panel is seen first on the shelf. Tell us how the carton will stand or hang, and we position the tucks and glue seam away from it.
Plan the information panels
Back and side panels carry barcodes, ingredients, directions and any text your product needs. Leave room for them from the start rather than squeezing them in at artwork stage.
Only add a window if it sells
A window is worth it when the product sells on colour or texture. Otherwise it weakens the carton and takes space from the artwork.
In detail
What separates a good carton from a poor one
Grain direction
Board is stiffer in one direction. Running the grain the right way on the sheet keeps panels flat and stops tall cartons bowing, and it is set when the dieline is laid out.
Clean creases
Creases must fold crisply without cracking the print. On dark full-colour designs, lamination helps stop the colour cracking along the folds.
Barcodes that scan
Barcodes read most reliably in a single dark ink on a light background, with a clear quiet zone around them. Tell us where yours sits at artwork stage.
Consistent reorders
The dieline, board and print specification are recorded against your approved proof, so a reorder of the same carton follows the same specification.
Finished work
Folding Cartons we have made
Straight Tuck End Boxes · Folding boxboard and SBS
Folding Cartons questions
Questions buyers ask
Anything not covered here, put it in the notes on your quote and we will answer it directly.
Ask on your quoteWhat is a folding carton?
A folding carton is a printed paperboard box cut and creased from one sheet, glued at a single seam and delivered flat. It squares up at packing, and the ends tuck, lock or glue shut. It is the standard box for most retail products.
What board weight do I need?
Most cartons use 300–400 GSM. Small, light items can use the lower end; larger cartons and heavier contents need heavier board. We confirm the board with your quotation once we know the product.
What is the difference between FBB and SBS?
Folding boxboard has a bright coated top and a bulkier middle layer, so it is stiff for its weight. SBS is bleached all the way through, giving white cut edges and a clean inside. Both print well; SBS is often chosen for premium cartons.
Which closure should I choose?
For light products a straight or reverse tuck end is the most economical. For heavy or glass products choose a crash-lock or snap lock base. For peg display, add a hanging tab. If you are unsure, tell us the product and how it is sold.
Can you make cube, pyramid or other shaped boxes?
Yes. Cube boxes are cartons with equal sides, and pyramid and other shaped boxes are drawn as custom dielines. If the shape folds from one flat sheet, it can usually be made as a folding carton.
Can I have a window in the carton?
Yes. A die-cut window can be left open or patched with clear film. We position it so the carton keeps enough strength around the opening.
What is the minimum order for folding cartons?
The minimum order is 50 boxes. Unit cost falls noticeably as quantity rises, so ask for two or three quantities on your quote request if you are deciding.
How long does a folding carton order take?
It depends on the style, finishes and quantity. Artwork approval, printing, finishing, cutting and gluing each take time. Tell us your required delivery date and our team will confirm whether the timing is achievable.
Can you match a carton I already use?
Yes. Send a flat sample or the dimensions and style of your current carton and we will reproduce the structure, and improve it where you want changes.
Ready to specify your packaging?
Our team replies during business hours, 10:00–18:00 UK time.