Stick packs & sachets
Review the number of units, their filled dimensions and the arrangement inside the carton.
CUSTOM PRINTED OUTER PACKAGING
Folding
cartons.
Built around the contents.
Matched to the way you pack.
Bring stick packs, pouches, bottles or product kits together in a printed outer box. Choose the loading method, carton structure and paperboard together.
Carton quantities, tooling and production timing are confirmed for your project.
START WITH WHAT GOES INSIDE
One box. The right fit.
Pouches & bottles
Allow for the filled pack, caps or closures, handling clearance and any insert needed to hold it in place.
Kits & coordinated packs
Share the full contents and packing sequence so the structure can be reviewed as a complete pack.
CHOOSE THE PACKING WORKFLOW FIRST
By hand.
Or on the line.
A carton that is easy to fill by hand is not automatically ready for a cartoning machine. The structure and board need to work with the actual packing process.
MANUAL PACKING
Flexibility at the packing table.
Consider hand packing when arranging mixed kits, developing a launch or changing formats frequently. Review the assembly steps, handling effort and required output.
- Open & erectThe operator squares the carton and forms the base.
- Load the contentsPlace the units or inserts in the agreed arrangement.
- Close & checkTuck, lock or glue as specified; check fit and closure.
Review: Ease of opening, number of folding steps, packed weight and how securely the base holds the contents.
MACHINE PACKING
Consistency through each cycle.
Specify the carton around the selected line. End-load, top-load and wraparound systems handle the pack differently; machine closure can use tuck or glue systems.
- Feed & formThe feeder or forming station presents the carton consistently.
- Load in positionThe product and carton must fit the machine’s loading path.
- Close & dischargeFlaps, glue areas and clearances match the closing station.
Review: Machine model, approved dieline, feed orientation, board caliper, grain direction, crease quality and opening force. Evaluate production-representative samples on the intended line.
SEE HOW THE PACK WORKS
A flat sheet.
A finished pack.
The dieline defines the structure. The packing process erects, loads and closes it.
THE CLOSURE IS PART OF THE DESIGN
Choose how
the box takes shape.
These are common structures to discuss, not a list of universally interchangeable boxes. Confirm the dieline, board, packed load and packing method together.
Tuck-end
Top and bottom flaps tuck into the body. Straight and reverse tuck styles differ in flap orientation.
Discuss: Hand packing or a compatible machine, opening direction and flap clearance.
Auto-bottom / crash-lock
A pre-glued base forms as the flat carton is squared up, reducing separate bottom-folding steps.
Discuss: Fast erection, base engagement and the actual packed load.
1-2-3 / snap-lock bottom
Bottom flaps are folded and interlocked in sequence. This differs from a pre-glued auto-bottom.
Discuss: Manual or suitable semi-automatic assembly and the steps needed to secure the base.
Seal-end / glue-end
End flaps are closed with the specified adhesive system rather than relying on a tuck closure alone.
Discuss: The closing equipment, adhesive, flap layout and bonding areas.
BALANCE APPEARANCE, STRENGTH & HANDLING
What is the
carton made of?
Compare these common paperboard families, then confirm the available grade for your project. A white surface alone does not identify the fibre composition or performance.
BLEACHED FIBRE
SBS / SBB
Solid bleached paperboard uses bleached chemical pulp and provides a white base for printed graphics. Coated faces and grade details vary.
Compare: Print appearance, inside colour, caliper, stiffness and the selected finishing process.
MULTILAYER PAPERBOARD
FBB
Folding boxboard combines a mechanical-pulp middle with bleached chemical-pulp layers. White-back and cream-back grades are available in the market.
Compare: Bulk, stiffness, back shade and crease performance using the actual grade data.
RECYCLED-BOARD FAMILIES
CRB / WLC
Coated recycled board and white-lined chipboard are families of recycled-fibre board. Names and constructions differ between markets and grades.
Compare: Actual recycled content, face and back colour, caliper, strength and intended use.
UNBLEACHED FIBRE
Kraft-based board
Unbleached board can give a natural brown appearance. Coated unbleached kraft (CUK) can pair a coated print face with a brown back.
Compare: The actual grade, print surface, colour treatment and strength needed for the contents.
GRAMMAGE · g/m²
Weight per area.
GSM describes the board’s mass per unit area. A higher number alone does not guarantee a better carton or better machine performance.
CALIPER · THICKNESS
The space the board takes.
Specify thickness alongside stiffness, grain direction and crease design. Boards with the same GSM can behave differently.
Swatches illustrate board families, not exact layer thicknesses or production specifications. For direct product contact, share the intended use so the complete material and finish can be reviewed.
TURN THE STRUCTURE INTO YOUR PACK
Print, finish
and convert.
Our carton manufacturing partner’s presentation shows printing and conversion capabilities. The selected board, artwork and structure determine the process for your order.
Your brand presentation.
Discuss offset printing, varnish and UV effects, film lamination, foil stamping and embossing. Confirm colours and surface feel with suitable proofs or samples.
Details that shape the box.
Die-cutting, creasing and folder-gluing turn the printed sheet into the agreed carton. Review glue areas, folds and finishing layers together.
Appearance and use.
Review print, die-cut alignment, folding and glue quality alongside filled-pack fit. A visual mockup is not a machine acceptance test.
YOUR PACKAGING CHOICES
Paper, board & decorative finishes.
Choose the structure first, then the print surface and finishing sequence.
View more paper and finishing references
Coated gloss & matte paper
Gloss coated paper and matte coated paper offer different print surfaces. Discuss these for printed wraps or inserts; do not equate a coated sheet with a specific carton-board grade.
White card & grey-back board
White card and white-faced grey-back board provide different face and reverse appearances. Confirm the actual grade, caliper and crease performance.
Brown & white kraft
Brown kraft and white kraft create different background colours for artwork. Confirm the print surface and suitable board or wrap construction.
Metallic & pearlescent paper
Gold/silver card and pearlescent paper offer decorative surfaces. Review colour proofs and folding behavior on the actual material.
Greyboard & corrugated board
Greyboard supports wrapped rigid-box constructions; corrugated board uses a fluted structure. These are separate constructions from a folding carton.
Specialty papers & inserts
Specialty paper and translucent tracing paper can be discussed for wraps or presentation layers. Uncoated offset, lightweight coated paper and woodfree paper are also listed as general print-paper references, not interchangeable carton boards.
Five groups of printing and finishing choices
Printing
CMYK process printing, spot-colour printing and screen printing. Specify colour targets and review proofs on the actual paper.
Raised, recessed & textured
Embossing/debossing, texture embossing and flocking create different tactile effects. Review depth, placement and how the finished panel will fold.
Surface effects
Spot UV, reverse UV, reverse frosting, gloss/matte film lamination, varnishing and glitter treatments. Compare a physical finish sample and coordinate folds and glue areas.
Foil & edges
Gold/silver hot foil and edge painting add accents. Confirm foil colour, minimum detail and alignment with print or embossing.
Cutting & folding
Die-cutting defines the outline; dotted/perforation lines create a controlled tear or fold feature as specified. Keep these distinct from structural crease lines on the approved dieline.
The supplied paper-and-process presentation is a general reference. It does not establish that every option is available from the carton manufacturer. Confirm board grade, decoration, direct-contact use, tooling, samples and quotation as one specification.
START WITH THE INFORMATION YOU HAVE
A useful brief.
A better starting point.
No finished specification yet? Start with the contents and packing plan.
Minimum quantities, tooling, sample arrangements, materials and production timing are confirmed in the carton quotation.
- Contents & fitUnits per box, filled-pack dimensions, total weight and any insert.
- Packing methodHand or machine packing; machine make/model and loading/closing method if known.
- Structure & materialA current carton, approved dieline or board specification, if available.
- Artwork & orderQuantity per design, desired finish, destination and target arrival date.
BEFORE YOU FINALIZE THE BOX
A few useful
answers.
Does auto-bottom mean machine packing?
No. It describes a pre-glued base that forms when the carton is squared up. It can make hand erection easier. Machine suitability depends on the complete structure and equipment.
Can one carton work for hand and machine packing?
Potentially, if the structure, material and closing method suit both workflows. Confirm the machine requirements before fixing the dieline, and evaluate production-representative cartons on the intended line.
Should we choose the highest GSM?
Not by GSM alone. Board grade, caliper, stiffness, grain direction, crease quality, contents and packing method all affect the result.
Do the rollstock minimum and 30-day production time apply?
No. Those are rollstock terms. Carton quantities, tooling and timing are confirmed separately for the chosen board, structure and artwork.
Can we use the stick-pack artwork template for a carton?
No. A carton needs its own confirmed dieline, including cut lines, folds, glue areas and artwork allowances. Share your current drawing or request the layout for the agreed carton.
Further reading on cartons and paperboard
These independent manufacturers explain general material and equipment principles; their product specifications are not Encap’s supply terms.
ONE PRODUCT. COORDINATED PACKAGING.
Plan the whole pack.
Tell us about the primary pack and the carton around it.