Recently we create a design for a heavy duty corrugated box, which is only 25mm in thickness. The package is supposed to hold an item around 3.5kg steel spike inside. The requirement for the box structure and the paper material are both very high. After a week test and research, we finally find a solution.
There are 3 challenges for us to create the structure design for this corrugated printed box. Firstly, the thickness, that is, the width of the paper box is only 25mm in thickness. It means that we can not use the traditional method to glue the side panel of the package. The paper box would be difficult to bend and fold. Also, there might be cracks on the edge of the corrugated box. And it turns out that the F flute is the best solution with the perfect combination of strength and flexibility. Secondly, the box will carry a very heavy steel spike inside. The weight is around 3.5kg. It means that we need choose a very good F flute corrugated board to produce the corrugated box. Thirdly, there is a hanging hook, hanging tab on the top of the box. The hook need to be well designed, then the hook won’t break during the delivery process.
In order to solve the first problem, we use a self lock structure to replace the traditional glue method to close the box on the side. In case that the spike may fall out of the box, we use a special tuck end box structure at the end to seal the bottom very tightly. For the paper material, we use the very strong corrugated board, then it can have the best printing effect and strength.
The box has the blue tone outside. It is CMYK full color printed box with the glossy laminating to protect it from the slight water or humidity influency.