Guideline for Determining Dimensions - There is a proper sequence to describe the dimensions of a carton:Length x Width x Depth
remark:W=width L=length H=highet G=gusset
To determine the proper length, width and depth, place the carton facing you with the opening pointing up (as if the carton was to be filled from the sky).
Length - the longest open end dimension from left to right
Width - the shortest open end dimension from front to back
Depth - the remaining dimension from top to bottom
When measuring always refer to the outside dimensions of the carton. Please measure from the center to center of the scores. Also, dimensions should be rounded to the nearest 1/16th of an inch.
The bottom piece of the package that typically contains items
A chipboard piece that has been cut to size, scored, and corners removed so the piece will form a component when folded.
An area of ink or color that extends past the perimeter of the area to be printed.
Terms that refer to mill coated paper. C1S indicates the paper is coated on one side only, C2S is coated on both sides.
The basic structural material from which the package is constructed. It is primarily comprised of recycled fibers and can be specified in a wide array of calipers, finishes, and several standard dyed colors.
Protective finishes applied to paper. Some paper is manufactured at the mill already coated on one or both sides providing a smooth, finished appearance. There are additional coatings which can be applied over printed sheets to provide further protection of the surface. They are:
Film Lamination is a separate sheet of material, usually nylon, polyester or acrylic applied to the sheet. This coating provides the best protection for the printing, is available in a variety of finishes, is extremely durable, and is applied to the entire sheet.
UV (Ultraviolet) Coating is applied to the sheet in liquid form and cured under UV light. It shares many of the appearance attributes of film lamination but is not as durable. It is also available in a variety of finishes and can be applied to specific areas of the sheet, referred to as "spot UV".
Aqueous Coating is a water based coating applied to the sheet in liquid form that provides a very smooth finish and good protection for the printing. It is available in a variety of finishes and is applied to the entire sheet.
Varnish is a petroleum based coating applied to the sheet in liquid form that provides a smooth finish and generally adequate protection for the printing. It is available in a variety of finishes and can be applied to specific areas of the sheet, referred to as "spot varnish".
We will assist you in selecting and specifying the best paper(s) and/or coating to achieve your desired appearance as well as protection for your packaging
A hot stamp that applies color and raises (embosses) the colored area simultaneously.
Depressing the surface, or a portion of the surface of paper. A process similar to embossing but where the design is impressed into the surface of the sheet or component.
Terms that refer to a mechanical drawing of a wrap or component showing all events such as folds, creases cuts perforations and bleed(s).
Raising the surface, or a portion of the surface of paper. Embossing can be applied to the entire sheet in a variety of patterns, for example textiles, leather and wood. Embossing can also be applied to the sheet in specific designs, such as a logo or text, without the use of pigments. This is referred to as Blind Embossing.
The portion of a blank that forms the sides or ends of the component, giving it depth when folded upright. It is also referred to as the rim.
Any portion of a construction that hinges to an adjacent component such as a flap lid, which is a flat piece of board, wrapped and hinged to a base.
A hot stamp that applies only color to the surface of the paper.
A term that refers to a base and cover having the same length and width, creating smooth sides where the cover rim does not extend past the outside perimeter of the base.
A component that attaches two pieces of the package together but allows movement of one or both pieces along it axis. For example a lid may be hinged to a base. Hinges are constructed in a
variety of methods or can be a separate component.
A process by which metallic or colored foil is transferred to the surface of paper by a heated die or plate.
Any component placed or adhered into a construction that prevents movement and/or provides separation of the packaged piece(s). Inserts can be formed from soft or rigid foam, chipboard, and plastic.
The top piece of the package that covers the items and/or the base.
A process in which only the edges of the wrap are adhered to the base and/or cover, creating envelope folds at the corners. Loose wrapping most closely approximates a hand wrapped appearance, such as in gift wrapping.
A tray which fits into a base and extends past the upper rim to provide an alignment surface for a flush fit lid.
A chipboard piece that elevates the item(s) within the base. Platforms may be die cut to prevent movement of items.
Any method of testing and verifying artwork prior to production of plates, dies and tooling.
PVC(Poly Vinyl Chloride):
A plastic material used to create see through lids. It is available in a variety of colors and thicknesses.
A groove cut into, but not all the way through chipboard, along which the board is folded.
Set Up Box(Rigid Box):
A box that is manufactured and shipped in its final configuration, ready for use without further unfolding or assembly by the end user.
An open ended case into which book(s) or other printed materials are inserted.
The back of a bound book or the narrow back of a slipcase.
A reinforcing tape applied to the corners of a component.
A term that refers to a lid that fits over a base or "telescopes". A full telescope box is one in which the base and cover depth are the same.
A process in which the entire surface of a wrap is coated with glue and adhered to the base and/or cover.
A base with no lid.
A sheet of material used to overwrap the chipboard base and/or cover such as paper or fabric.
How to Make a Set-Up Box
Two Radically Different Approaches to Packaging
Before we investigate the actual manufacturing process, let’s consider the differences between a folding carton and a set-up box. At first glance, it may be difficult to tell them apart. The base and lid on the left look pretty much the same as the boxes on the right.
Take a closer look, however, and you’ll see that the panels on the box on the left have been folded over to make up the box. The lid on the right is made from a single piece of chipboard, cut-scored to fold, with the sides held together by tape. The sample on the left is a folding carton; the one on the right is a set-up box.
A set-up box can be distinguished from a folding carton in three major ways:
❒ Once manufactured, a set-up box will not collapse like a folding carton, hence its other interchangeable name –rigid box.
❒ The chipboard substrate used for the walls of a set-up box is as much as four times thicker than the paperboard used to make a folding carton.
❒ Unlike folding cartons, printing is rarely applied to the chipboard, but rather to a separate “wrap” of paper which is then adhered to the plain box.
A wide variety of wrapsmay be applied to a set-up box, including padding, leather, fabric and flocked (a decorative finish accomplished by applying fine fiber particles to the adhesive coated surface of the paper).
Each type of paperboard packaginghas its uses. Here is a comparison of some of the advantages of each method of manufacture.
Set-up boxes have been in use since the late 1800’s. Today, there are many variations of possible styles, some of which are illustrated below. For our purposes, we will describe the manufacture of the most basic style, the wrapped set-up base and lid.
Non-bending chipboard, the material most often used for rigid boxes, may range from .040 (40 thousandths of an inch) to .080 or more. Compare this to folding cartons, whose stock may vary from .010 to .036. Note that there are many types of substrate used by folding cartons depending upon the end use of the packaging, but most set-up boxes use chipboard. This is because in set-up box manufacturing, the finishing is done to the wrap, not the substrate.
The exception is when a material called white vat-lined chip is used. In this case, the chipboard is lined on either one or both sides with a white coating made from newsprint, giving the box a more finished appearance. This stock works especially well if the interior of the box is to remain unfinished, or unlined. By contrast, Image 5 shows somesamples of lined boxes.
The goal in set-up box manufacturing is to bring the wrap and the formed chipboard lid or base together, adhering them in perfect alignment before forming the finished tray. Of the six fundamental steps in the production of a set-up box, two make the box, two produce the wrap, and two bring them together to produce the tray: for the tray –scoring and staying; for the wrap —printing/preparation and applying adhesive; and finally, for the completed tray -spotting and wrapping
Cutting and Scoring
We start with a cut-scored tray, which depending upon the box’s dimensions.
The simple steel rule die for the tray contains knives (the black lines) for cutting out the overall shape from the chipboard, and cut-scores (the red lines) for allowing the panels to fold. Cut-scores only partially penetrate the chipboard, allowing bending without tearing.
Set-up boxes can be made without stay tape, but for added stability, ¾” wide adhesive backed tape is applied to the four corners of the tray on a machine called a quad stayer. Two of the four rolls of tape are clearly visible; the other two are blocked by the ones in front. The chipboard blanks are fed into the machine, a plunger forms the box, tape is applied and heat-sealed to the tray.
Not all set-up box wraps require printing, but this option, plus foil stamping, embossing, debossing and other decorative techniques; almost anything that can be glued to chipboard and formed into a box are available.
Whatever wrap is used, it must be trimmed before adhesive is applied. The corners are cut away or mitred so that when the box is formed, the wrap makes a perfect transition from two-dimensional blank to three-dimensional box.
There are two methods of adhering the wrap: tight wrap, the most typical technique; and loose wrap. The tight wrap method applies adhesive to the entire back surface of the wrap. In Image 7, a corner cut wrap has just left the gluer on its way to the spotting station, where the formed lid or base will be positioned and placed onto the wrap. Loose wrap is generally applied only to the lid of a box, and as the name implies, the wrap is only spot-glued at the edges, leaving the top panel without adhesive. The purpose of this type of gluing is primarily aesthetic: a box made with a loose wrap
appears to be hand-made, and therefore a more expensive package. Back when much of the production was indeed done by hand, loose wraps were more common. But in today’s automated environment, loose wrap constitutes only a small percentage of total production.
This brings us to the last two stages of production, where the wrap and tray meet to become a finished piece.
Completing the Lid or Base
The term spotting is derived from the days when an operator would position, or spot the lid or base onto the wrap, “eyeballing” the correct position. While this operation is still done manually in some operations, with the advent of electronic eyes and more sophisticated positioning equipment, the process is becoming more and more automated.
The wraps, adhesive-side up, move along a conveyor from the left. The lid or base, having been formed in the quad stayer, moves toward the operator from the top of the diagram. The operator then carefully (and quickly) places the tray onthe glued surface of the wrap. From there, the box moves to the right toward the wrapping station.
In an automated line, the spotting station appears as it does in Image 8. If you look closely at the top center of the shot you can see a machine-positioned base descending toward the wrap below. At the bottom left of the picture is a base that has just left the station, now ready for wrapping.