Roll End Tuck Top (RETT) and Econo boxes (often colloquially called mailers) are die cut boxes that are unglued and easy to assemble. These boxes is extremely rigid because the rolled sides consist of 3 layers of material once assembled. RETT's have a connected lid and front panel that can be secured between the two side panels without glue or tape via the optional cherry locks. The top lid also has optional dust flaps that remove all rough edges on the top lid, with the added benefit of keeping the inside cleaner. The main advantage of both RETTs and Econos is that they are extremely versatile, and can designed with customized inserts made from foam, plastic, pressed pulp, or corrugated. Custom inserts are a great way to keep your product secure during shipping, and provide a better unboxing experience for your customers.
When to use:
- Monthly subscription or influencer kits
- Direct to consumer sales
- Promotional giveaways
- Shipping small fragile objects
Custom Die Cut Boxes
Die cut boxes are just like other boxes, only they are die cut! Well, what does that mean? Here is a helpful video explaining what the cutting dies and other tooling charges you might see on your quote are. Since you didn't watch the video, all you need to know is that a cutting die is essentially a large cookie cutter that cuts your box out of a sheet of corrugate or chipboard. All displays and most custom boxes, which are not manufactured using digital technology, need to be die cut. The exception is RSC style boxes, however, even certain variations of RSC type boxes need to be die cut. For example, a cutting die is always needed if the artwork goes over the scores (folded areas), if the box has windows or tapered flaps, or if the box has an auto bottom, snap lock bottom, or anything other than RSC style flaps. The example Gurunanda box shown here needed to be die cut because it has a window and non-standard top and bottom flaps.
When to use:
- Certain design features are needed that are not available with RSC type boxes.
- Generally anything besides a master case.
There are several different styles of trays, but the main distinction is whether the tray is glued or unglued. The most commonly used unglued tray design has roll ends or sides with locking tabs, which make them both cheap to manufacture and easy to assemble. There are various unglued tray designs, but all are intended for smaller runs, hand packing, or when a case erector is either not available or too expensive. A glued tray can either come pre-glued or unglued with the intention of being glued on a case erector. The main advantage of a pre-glued tray is faster packing when compared to a roll end/side tray. However the added manufacturing time required to pre-glue trays does increase the cost per unit. Glued trays designed for assembly via a case erector are the cheapest to manufacture, and are generally used for larger runs. It is best to weigh all of your fulfillment options before making a decision about what style tray is right for you. All of our trays are manufactured with sturdy corrugated sheets help reduce the chances of warping or tearing, and keep the product safe from damage during transit.
When to use:
- Product is packaged in cans or bottles
- Product will be palletized and sent to distributors or retailers directly
Custom RSC Boxes
Regular Slotted Containers (RSC) are THE standard when it comes to boxes, and are primarily used as shipping and storage boxes. Unlike the RETT and Econo, this style of box requires either tape, glue, strapping, or staples to seal shut. RSCs are ubiquitous due to the versatility of the design in combination with its simplicity, economy, and functionality. There are many different ways that an RSC can be customized beyond size and board test. RSCs can be easily modified into different styles of boxes depending on the flaps, such as: All Flaps Meet (AFM), Half Slotted Container (HSC), or FOL (Full Overlap). These modifications are used for a variety of different reasons, and add to the overall versatility of this design. We can customize RSCs using different printing methods such as direct print (2 color over white shown here), lithographic labeling, and direct print on Kemi board. The best option for you depends heavily on your artwork and the quantities you are looking to order.
When to use:
- Master cases for palletization
- Direct Shipping
- Retail boxes for larger products
A Pretty Darn Quick (PDQ) tray is a type of corrugated tray that is typically shipped out pre-loaded with product so that it arrives to the store retail ready. PDQ trays are typically used for pallet displays, shelves, and end cap displays. This style of tray is most commonly found at big box retailers, grocery chains, and home improvement stores because they make product more visible to consumers and promote impulse buys.
When to use:
- When space is limited
- Provide high visibility
- Promote impulse purchases