Box Structures
Secondary Packaging Folding Carton Systems and Box Structures for Consumer Brands
Standard Straight Tuck Mono (STI)
Lightweight Folding Carton for Low-Load FMCG Products
Standard Straight Tuck Mono (STI) is a cost-efficient folding carton structure designed for lightweight FMCG applications. With same-direction top and bottom tuck flaps, this structure provides clean retail presentation, controlled board strength, and efficient material utilization for compact consumer product formats.
It is best suited for products with moderate handling requirements and limited stacking pressure exposure.
- Recommended for up to ~200g packed weight
- 250–350 GSM folding carton
- Ideal for retail & distributor supply
Auto-Lock Bottom Mono (ALB)
Reinforced Folding Carton for Higher Load Applications
Auto-Lock Bottom (ALB) is a pre-glued folding carton structure designed for products that require stronger bottom support and improved packing efficiency. The crash-lock base enhances load stability and reduces collapse risk under stacking and courier handling conditions.
It is recommended when product weight, height leverage, or distribution pressure exceeds standard tuck performance.
- Suitable for products above ~200–250g packed weight
- 300–400 GSM board (based on load requirement)
- Better stacking resistance & bottom strength
Reverse Tuck End Mono (RTE)
Balanced Folding Carton for Mid-Load Applications
Reverse Tuck End (RTE) is a folding carton structure where the top and bottom tuck flaps close in opposite directions, providing balanced closure behavior and controlled bottom stability. This format offers improved structural performance over same-direction tuck systems while maintaining efficient material usage and clean retail presentation.
It is recommended when product weight and distribution handling exceed lightweight tuck limits but do not require crash-lock reinforcement.
- Suitable for products between ~150–300g packed weight
- 250–350 GSM board (based on load requirement)
- Improved bottom stability vs standard tuck
- Suitable for retail & moderate distribution handling
Combo Folding Carton (2-Pack / 4-Pack / 6-Pack)
Multi-Unit Folding Carton System for Bundled FMCG Products
Combo Folding Cartons are multi-unit secondary packaging structures designed to hold 2, 4, or 6 primary products within a single outer carton. The outer structure is selected based on total packed weight, while internal partitions are engineered to control movement and distribute load evenly.
This system is recommended when multiple units are sold together and structural stability, stacking pressure, or transit vibration must be managed effectively.
- Suitable for bundled products with total packed weight ~300g–1.2kg
- 300–400 GSM board (based on total load & distribution model)
- 300–400 GSM board (based on total load & distribution model)
Tray + Sleeve Folding Carton
Two-Piece Folding Carton for Premium Presentation
Tray + Sleeve is a dual-component folding carton system consisting of an inner tray and an outer sliding sleeve. The tray holds the product securely, while the sleeve provides a clean exterior finish and controlled reveal during opening.
This structure is recommended for presentation-focused packaging where retail display, brand experience, and compartment-based layouts are key considerations.
- Suitable for lightweight to mid-weight products (~100g–500g)
- 300–400 GSM board
- Optional compartment inserts for multi-unit formats
Cigarette Style Folding Carton
Compact Multi-Unit Packaging Structure for Sachets, Samples & Discovery Kits
A cigarette-style folding carton is a compact packaging structure designed to organize multiple units within a single retail-ready carton while providing controlled dispensing and an enhanced unboxing experience. The format combines efficient space utilization, strong shelf presentation, and convenient product access, making it suitable for products sold in multi-unit configurations.
- Suitable for lightweight products (~50g–150g)
- 250–350 GSM board
- Addition die-cut inserts for clouser
Magnetic Rigid Box with Foam Insert
Premium Protective Packaging Structure for Fragile, High-Value & Precision Products
A magnetic rigid box with foam insert is a premium packaging structure designed to securely hold products within custom cavities while providing enhanced protection, product organization, and a premium unboxing experience. The structure combines rigid board construction, magnetic closure, and foam inserts to help reduce product movement during handling and transportation.
Commonly used for healthcare products, glass ampoules, diagnostic kits, electronics, wellness kits, luxury products, and corporate gifting applications.
- Suitable for fragile and premium products (~50g–2000g+)
- Rigid board construction with custom foam insert system
- Magnetic closure for premium presentation and repeat usability
Large Format Food Tray Carton
Multi-Container Folding Carton for Food & Gifting Applications
Large Format Food Tray Cartons are custom folding carton structures designed to hold multiple food containers while providing a practical carrying format and branded presentation. The structure can incorporate reinforced bottoms and integrated handles based on the product load.
It is recommended for multi-unit food packaging where product fit, carrying convenience, presentation, and structural stability are key considerations.
- Suitable for multi-container food packs & hampers
- 350 GSM board or corrugated construction based on load
- Optional Auto-Lock Bottom & bottom taping for added support
Die-Cut Window Carton
Product Visibility with Premium Retail Presentation
A Die-Cut Window Carton is a folding carton structure featuring a precision-cut opening covered with a transparent PP film, allowing customers to view the product while keeping it protected. It enhances shelf appeal, builds consumer confidence, and creates a premium retail experience without compromising product integrity.
It is recommended for products where visual presentation influences purchasing decisions.
- Transparent PP film for clear product visibility
- Custom window shapes and sizes based on product design
- Ideal for retail display, gifting, and premium consumer products
Printed Corrugated Box
Branded Shipping Box for Protection & Product Presentation
Printed Corrugated Boxes are durable shipping cartons designed to protect products during storage, transportation, and courier delivery while showcasing your brand through high-quality printing. They combine structural strength with professional presentation for retail and e-commerce packaging.
It is recommended for businesses that require reliable transit protection while reinforcing brand visibility throughout the supply chain.
- Suitable for ecommerce, retail, and industrial products
- Available in 3-ply, 5-ply & 7-ply board options
- Custom printing for stronger brand recognition
Top & Bottom Rigid Box
Two-Piece Premium Rigid Box for Luxury PackagingProduct Visibility with Premium Retail Presentation
Top & Bottom Rigid Box is a two-piece premium packaging structure consisting of a separate lid and base. The rigid construction provides exceptional strength, while the removable lid creates a refined unboxing experience and enhances the overall presentation.
This structure is recommended for luxury packaging where premium branding, product protection, and gifting presentation are key considerations.
- Suitable for premium products, gift sets, and luxury retail packaging
- 1.5–3 mm grey board with premium wrapping papers
- Optional EVA foam, paperboard, or fabric inserts for product protection
Ring & Flap Box Structure
Efficient Large-Format Packaging for Premium Products, Gifting & Shipping Applications
A Ring & Flap box is a packaging structure designed to accommodate larger products while maintaining efficient material utilization, simplified assembly, and a premium presentation experience. The structure combines a tray-style base with integrated flap closures, making it suitable for products requiring larger pack dimensions and enhanced structural performance.
Commonly used for premium fruit packaging, corporate gifting, festive hampers, dry fruit boxes, apparel products, subscription kits, and large-format retail packaging.
- Suitable for medium to large product formats
- Can be developed using duplex board, corrugated board, or hybrid constructions
- Flat-pack friendly for efficient transportation and storage
Master Carton Engineering
Corrugated Transport Carton for Load & Stacking Performance
Master Carton Engineering focuses on the structural design of corrugated transport cartons used to carry multiple secondary folding cartons during storage and distribution. Board selection, ply strength, and internal layout are evaluated based on total packed weight, stacking height, and transit conditions.
This system is recommended when compression resistance, pallet optimization, and transit protection are critical to maintaining product integrity across the supply chain.
- 3-Ply / 5-Ply / 7-Ply corrugated board (based on total load)
- Flute selection engineered for stacking & vibration control
- Designed for palletized distribution and bulk handling
