With over 30 years of experience in corrugated box design and construction, at The Box Factory, we are able to truly offer a service like no other.
Our designers create bespoke boxes that work for your products, no matter the shape.
Navigating the custom design of cardboard boxes can be a complex and tedious task, however our design experts are on hand to offer assistance throughout the complete design process, creating beautiful packaging that aligns with individual brand values and product specifications, across almost any application.
The cardboard box design process begins with an initial consultation, usually consisting of detailed discussion to better understand your specific requirements, including from budget to product details, branding (colours, message, style and tone) to shipping demands and goals to timeframe. Once we understand your product details; size, shape, weight, fragility and any specific handling needs, our designers are able to consider the most efficient use of material, to ensure the protection of said product.
Remaining environmentally conscious is of utmost importance to us at The Box Factory and l our boxes can be made from fully recycled material from FSC certified forests. Our designers take into consideration the environmental impact packaging can have, and ensure the materials used align with your personal brand identity and message.
Based on the information gathered, we then move into the cardboard box design concept development stage. Using the latest in Computer Aided Design (CAD) technology and traditional sketches, a series of initial concepts will be produced, taking into consideration box styles, sizes and structural integrity. These visual aids are integral at this stage, as it gives a clearer image and you the ability to visualise the concept and give crucial feedback; highlighting preferences and suggesting modifications.
A sample speaks a thousand words, once all parties are satisfied with a concept or series of concepts it is possible to enter the Prototype and Testing stage. Even with CAD renders, a prototype is integral in ensuring correct use of materials and finishes. Materials throughout the industry have evolved and are often interpreted differently from supplier to supplier, therefore a sample ensures we are comparing ‘apples with apples’, and invites you to get a more informed idea of how the box designs look, feel and function.
It is also possible at this stage to vigorously test the proposed design, ensuring functionality, ease of use and most importantly durability for the boxes unique requirements, no matter the application and can conform with shipping and handling requirements.
Once testing is complete and we have received final design approval, the design moves to the final stage, box manufacture. A production process is put in place; including details on material selection, printing, die-cutting, folding, and gluing etc.. Our completely automated factories ensure this is a seamless process. With our team completing rigorous quality control measures throughout the process to ensure the final product meets exceptional standards.
Print is much more than ink on paper or cardboard, it adds value and a touch of luxury to your boxes and can be used as a powerful tool to elevate your brand. From subtle logo placements to vibrant, full-colour designs, both inside and out, our in house printing department is capable of reinforcing your brand image with striking high quality print.
Flexo printing is renowned for its versatility, speed and cost-effective nature, making it the perfect option for large quantity print and fast lead times. A succession of print stereo plates are made, depending on the number of colours required for the print, ink is applied using a rotating cylindrical plate, and the image is transferred as the plates come into contact with the cardboard substrate. Our specialised Casemaker machines are capable of printing up to 4 colours in a single pass and we have the option to print two internal and two external colours to the box.
Our skilled colour technicians are capable of matching any Pantone colour swatch or specific brand colours measuring base inks, pigments and additives to achieve a flawless and precise match. With use of specialised equipment such as spectrophotometers colour can be compared and quality assured. Our machine operators will quality check the print at the start and during the print run to ensure that it matches your approved artwork and therefore delivering superior quality print, each and every time.
The European Federation of Corrugated Board Manufacturers (FEFCO) is a non-profit organisation representing the interests of the industry across Europe and addressing a wide range of issues, from technical topics to economical questions.
FEFCO created a recognised library of box styles that help assist packaging companies and their customers. When starting a new project always consider whether a pre-existing box style can be used or modified.
A FEFCO code is a four-digit code. The first 2 digits of the code represent the category style of the box. The second 2 digits the unique style of the box.
For example, an 0201 box is (02) - regular box, (01) - with flaps that close on both ends.
FEFCO codes launched in 1952, so their use is commonplace throughout the packaging industry. If you quote a FEFCO code, it allows us to understand your exact box requirements more quickly.
Not sure which design to use?
These standard styles are a great place to start but if you want something more bespoke then click here to complete our enquiry form, fill in a few details and we will be in touch to discuss further.
If you want to give us a call, our number is 01926 430510, we would be happy to hear from you.
