Types of Corrugated Boxes, Uses, and Compatibility

Types of Corrugated Boxes, Uses, and Compatibility

Types of Boxes for Packaging

Wayne Automation is committed to providing a complete picture of our products’ applicability. This article discusses the different types of packaging boxes, their applications, and how they fit into the systems we offer for your end-of-line packaging needs.

Back to Basics

 Flat stacked corrugated cardboard in a large warehouse

The corrugated cardboard trays, cases, and boxes we all know and love for their packaging applications begin with Kraft paper.

This ubiquitous product is the result of the kraft process, which produces a stronger paper.

Absent of dyes or bleach in the ways that printer papers are produced, it is also more cost-effective.

Corrugated cardboard is formed by sandwiching two sheets of kraft paper around the fluting (the ridged paper in the middle). The fluting supports weight, and crushes in the event of a fall to absorb energy and protect your product.

The types of corrugated boxes themselves can come in single-, double- and triple-walled varieties, with fluting variations ranging from 1/32” (F fluting) to ¼” (A fluting).

Types of Packaging Boxes

The traditional corrugated box packaging comes in a variety of configurations, often delineated by how their tabs overlap.

  • A Regular Slotted Container (RSC) is the most common, featuring topmost flaps of equal length to meet in the middle, with a single identical pair at the bottom of the container.
  • A Half Slotted Container (HSC) is similar in construction to the RSC but without top flaps for open storage of its contents.
  • All Flaps Meet, sometimes referred to as a Center Special Slotted Container (CSSC) is a variation on the RSC style, except both pairs of top flaps meet in the center of the container, providing an extra layer of strength with the cardboard.
  • 1-2-3 Bottom Container, also called a Snap Container, features 4 die-cut flaps that form the bottom of the container. The name arises from how the flaps “snap” into place under pressure created by the other panels. The bottom panel is not sealed but holds itself together. It is an effective option for those who don’t wish to bottom-seal their containers. Additionally, 1-2-3 containers can be manufactured in RSC and other top closure styles.

Open top trays on a factory floor on conveyor belt

In addition to containers, trays and baskets are the other primary varieties of corrugated cardboard containers. Octagonal bulk bins, for example, can transport large individual units, like watermelons at a supermarket.

Basket carriers and trays with internal partitioners are ideal for transporting beverages and glass bottles which risk bumping into one another.

Trays may come in one or two-piece configurations and are sometimes called Telescopic Boxes.

Machine Applicability

Corrugated boxes come in many types and sizes, and Wayne offers a wide selection of products for every packaging type needed across every industry.

For those requiring basket carriers in the beverage industry, we offer fully-automated Basket Carrier Erectors and Inserters.

Our automatic case erectors and partition inserters easily handle every type of case described above, with many able to handle RSC, HSC, and All Flaps Meet cases.

More unique case styles like Tablock can be accommodated by our MOD B, CE-20/30, and Tablock specialty case erectors. For trays, we offer a comprehensive lineup of tray formers, erecting single pieces, telescoping, triple-ended, and many more styles. Wayne’s JTF-10 is even available for pallet-sized jumbo trays.

Our case erectors require the box type to be presented as a KDF (Knocked Down Flat) – the manufactured joint is glued, but the box is collapsed. However, we will soon offer a case former that starts with an unglued, flat die-cut sheet as an alternate box solution for those who see value in this process over procuring KDFs.

Common Types of Corrugated Boxes

Regular Slotted Container (RSC) A very common box style. Ideal for general purpose packaging and shipment.

Half Slotted Container (HSC)
Same as the regular slotted container only without a set of flaps.
Ideal for interplant shipment, store displays, tray alternatives.

Overlap Slotted Container (OSC)
In this style, the length of the box is greater than the width. The sealed overlap helps to keep the outer flaps from pulling apart.
Ideal for packaging where the overlap seal prevents dust ingress.

Center Special Slotted Container (CSSC)
This style provides extra strength because both the top and bottom have double the thickness of corrugated board.
Ideal for shipping items where the protection of two layers of corrugation (top/bottom) is required.

Snap or 1-2-3-Bottom Container (ALB)
A style more convenient for small-volume shippers. The bottom is not fully sealed, so it may not be suitable for heavy products or concentrated loads.
Ideal for manual operations or reuse operations.

Integral Divider Container
This is a self-divided box. Technically a regular slotted container but with a pre-glued internal divider.
Ideal for packaging where additional stack strength and product protection is required.

Telescopic Boxes (Design Style Trays, Infold Trays and Outfold Trays)
Telescopic boxes have separate tops and bottoms that fit over each other or a separate body.
Ideal for temporary removable / reusable top protections.

A one-piece folder is when one piece of board is cut so that it provides a flat bottom, flaps to form the sides and ends, and extensions of the side flaps that meet to form the top.
Ideal for use with integrated packs and seal equipment.

Wraparound Blank
A wraparound blank is formed into a box by folding it tightly around a firm product. The finished box is essentially an RSC turned on its side so that the bottom and top are unbroken.
Ideal for use with integrated packs and seal equipment

Tablock Case
RSC Bottom case with top flap folded back and captured.
Ideal for reshippers, packaging lines that cannot handle a box with flaps up (like the RSC)

Industries and Applications

Every box has applications and industries for which it is especially well suited:

  • Beverage packaging is perhaps our oldest industry and still one we service today. Beverage packaging makes heavy use of open-topped trays with partitions inserted to protect each individual drink.
  • Glass and Plastic packaging works along many of the same principles, but with an eye towards safety since these products may be especially delicate.
  • Petrochemical packaging relies on safe, sealed containers for transporting often-volatile or corrosive materials. RSC’s, HSC’s and All Flaps Meet are common for this industry.
  • Food packaging runs the gamut from trays to cases. This is why we offer our wide array of machines and packaging variations to meet your packaging needs.

Get the Right Case Erector and Box Type for Your Business

If you’re actively comparing case erector options to automate the types of packaging boxes you need, check out our FREE Ultimate Guide to Case Erectors.

This ebook is a detailed guide on the many different aspects, models, and benefits of case erectors to help you select the right machine for your application.

Download a copy right now and learn what case erectors can do to make your packaging process more efficient!

What Do You Need Help With?

At Wayne Automation, we want to help you achieve the highest level of efficiency throughout your entire end-of-line process. Of course, the first step in creating an effective automated system is selecting the right machines for the job.

Regardless of what industrial packaging solution you may need, we welcome you to browse through our wide range of automated packaging machines and see how we can help you achieve your goals. Then give us a call. We will gladly take the time to answer your questions, arrange a plant tour, or set up a product demonstration so you can make the right decision for your company.

If you want to learn more about specific types of packaging boxes or how we can meet your needs, please reach out today!

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