How a Custom Corrugated Box Gets Designed, Step by Step

1. Measure the product. Record length, width, height, and weight. Note fragile points, sharp edges, and anything wet, cold, or oily.
2. Define the pack-out. How many units go in each box? How many boxes go on each pallet?
3. Map the shipping route. Parcel, LTL, or full truckload? Cold storage or high humidity? Export? Each route changes the board you need.
4. Choose a box style. Common styles include the regular slotted container (RSC, the standard four-flap box), half slotted, telescoping, and die-cut mailers.
5. Set inside dimensions. Box sizes are always inside dimensions, listed length × width × depth. Length and width describe the opening. Allow 1/8 to 1/4 inch of clearance around the product.
6. Select the board grade. Pick flute and strength for the weight and stacking load. Post 3 walks through this step.
7. Add inserts or partitions. Dividers, pads, and die-cut inserts hold parts in place and replace loose void fill.
8. Decide on print. Plain, one-color handling marks, or full branding. Post 5 covers print options.
9. Test a sample. Pack real product, run the sample down your line, and ship a few through your carrier. Many shippers follow ISTA test procedures for drop and vibration.
10. Approve the spec and the first run. Sign off on a written spec sheet. Inspect the first production run against the spec before releasing the full order.

• Two or three units of the actual product
• Your current box, with any damage photos
• Weekly or monthly volume
• How you ship and how high you stack
• Who packs the box and how (by hand, on a table, on a conveyor)

• Listing outside dimensions instead of inside dimensions
• Choosing board by price per box instead of stacking load
• Skipping the line test, then finding the box slows your packers

Bring us your product and your current box. We will take you through each step.

S&S Incorporated · Packaging made easy since 1965 21300 St. Clair Avenue, Cleveland, OH 44117 216-383-1880 · info@sspkg.com · www.sspackaging.com Monday–Friday, 7:00 AM–3:30 PM