The regular slotted container is the most common box style and is often used for shipping and storage. The flap width (the distance from the outer edge of the flap to the folded edge adjoining the box) is the same on all four flaps. The two outer flaps meet at the center when the box is folded, and these containers require glue, tape or staples to close. These boxes are the most economical to produce and create very little manufacturing waste.
The full overlap container is similar to the regular slotted container, but has flaps that extend across the width of the box. This overlap provides reinforcement that results in increased stacking strength and offers protection against rough handling. This style is often used when there is a considerable difference between box length and width, creating a large gap between the inner flaps. The overlap helps to keep the outer flaps from pulling apart.
The half slotted container is similar to the regular slotted container, but has flaps only on the bottom, leaving the top open. Trays are often used as lids for these containers.
Die cut containers incorporate special shapes or structural elements that cannot be achieved using the straight lines and right angle cuts of conventional scoring and slotting equipment. The unique designs of die cut boxes often involve angled or curved cuts, slots and scores, or other features, such as perforations and cut-outs. These designs are created using a steel-rule die to cut and crease the container into the final package.
These flat scored and slotted sheets have flaps on the sides and ends that fold and fasten to produce trays, which can be used by themselves or as lids for half slotted containers. Trays are often used to ship heavy, flat items and as reusable storage containers.
Pads are sheets of corrugated board that are used to protect or divide the contents of a box. They can be cut into any shape to help separate, cushion, suspend and fill irregular spaces within a container. Pads can also be placed against the inside walls of a box to offer additional stacking strength.