Comparing Plastic Bins vs. Corrugated Bin Boxes

Why Packaging Automation Compatibility Matters As more fulfillment centers, contract packagers, and manufacturers turn to automation, packaging that isn’t compatible with machinery becomes a costly bottleneck. From misfeeds on case erectors to jams in packing stations, poorly designed corrugated boxes slow down operations, increase error rates, and limit throughput. For high-volume brands and logistics operations, automation-compatible packaging isn’t optional—it’s a core part of the system. Common Points of Failure with Corrugated in Automation Systems Automation often fails not because the equipment is faulty, but because the packaging isn’t designed for machine handling. Common issues include: Poor dimensional tolerance: If the box flaps don’t align cleanly, case erectors and tapers will jam. Low board rigidity: Boxes made from lightweight corrugated collapse during suction or robotic pick-and-place. Inconsistent slotting and scoring: Uneven folds confuse sensors or result in skewed box geometry. Incompatible closure style: Designs like auto-lock bottoms or complex folds may not be machine-erectable. Structural Design Principles for Automation Compatibility ✔ Stick to Clean, Repeatable FormatsRSC and FOL boxes with precision scoring are ideal for case erectors and tapers. Avoid overly intricate die cuts or asymmetrical flaps unless they’re downstream of automation. ✔ Use Consistent Die-Lines and Slot DepthsMaintain tight tolerances on slot depth, flap width, and glue tabs. Variability in cutting leads to misfeeds on erectors or case packers. ✔ Right-Size the Box for ConsistencyBoxes should hold contents securely with minimal void fill. Automated packout systems are most efficient when the box requires no manual fitting or adjustment. ✔ Add Automation-Friendly FeaturesIf machine-packing is in use, design inserts or partitions that can be preloaded or nested without human intervention. Consistent entry points and fitment are key. Material Considerations ✔ Choose Higher Rigidity Board GradesBoards with better stiffness (e.g., 44 ECT or 275#) maintain shape during pick-and-place and resist deformation in automated erecting. ✔ Use Coatings Where NeededFor packaging that passes through friction belts or vacuum suction, a clay-coated or high-slip surface may improve feed reliability. ✔ Avoid WarpPoor storage conditions or low-quality material lead to box warp, which ruins automation compatibility. Store flat and dry, and use high-quality stock. Don’t Forget Print RegistrationAutomation often uses machine vision to scan barcodes or orientation markers. Digital or flexo-printed registration cues must be in consistent locations, with sharp contrast and no ink bleed. Variable data printing can also assist with lot tracking in automated pick-pack systems. Benefits of Automation-Compatible Corrugated Faster throughput with fewer jams or stoppages Lower labor costs due to minimal hand correction Better reliability in high-speed fulfillment environments Scalability when expanding SKUs or entering new distribution channels Final ThoughtsCorrugated packaging isn’t just a vessel—it’s a mechanical component in an automated system. Brands that optimize their box design, material spec, and print layout for automation reduce errors, increase efficiency, and lower cost per shipment. If you’re designing packaging for automation or reworking a manual process, Brown Packaging can help engineer corrugated solutions that perform in real-world fulfillment lines. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Corrugated Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts

In the world of packaging, there’s a constant pursuit of innovation and improvement to ensure products are not only securely packaged but also easy to access. One such advancement in packaging technology is the incorporation of cherry locks in roll end tuck top (RETT) boxes. In this blog, we will delve into the intricacies of cherry locks, exploring their design, features, benefits, and the scenarios where they prove to be an invaluable addition to RETT boxes. Understanding Cherry Locks Cherry locks, also known as snap locks or friction locks, are a locking mechanism employed in packaging to secure the top flaps of boxes without the need for additional adhesives or tape. These locks are specifically designed to offer a secure closure while allowing for effortless and repeated opening, making them ideal for applications where ease of access is crucial. Here’s a closer look at their design and features: Benefits of Cherry Locks Cherry locks offer several advantages, making them a valuable addition to RETT boxes: Enhanced Security: Cherry locks provide a secure closure that prevents accidental opening during transit while deterring tampering or unauthorized access. Easy Access: The user-friendly design of cherry locks allows for quick and effortless opening, making them ideal for products that need to be accessed frequently, such as retail items or subscription boxes. Sustainability: Cherry locks contribute to sustainability efforts as they reduce the reliance on single-use adhesives and tapes, promoting eco-friendly packaging practices. These boxes can also be reused and repurposed. Cost Savings: While cherry locks may initially seem like a slightly higher investment, their reusability ultimately leads to cost savings by eliminating the need for additional sealing materials. Cherry Locks in Roll End Tuck Top Boxes Roll end tuck top boxes, with their inherent durability and versatility, are a perfect pairing for cherry locks. These boxes are constructed to provide a secure enclosure while allowing for easy customization and branding. When cherry locks are integrated into RETT boxes, they bring an added layer of security and convenience to the packaging solution. Scenarios for Using Cherry Locks in RETT Boxes Cherry locks are a versatile locking mechanism that can be employed in various industries and applications: Retail Packaging: RETT boxes with cherry locks are an excellent choice for retail packaging, ensuring that products remain secure on the shelves while allowing customers to open and inspect them easily. E-commerce: For e-commerce businesses, cherry locks enhance the security of shipped items while offering recipients a hassle-free unboxing experience. Subscription Boxes: Subscription box services benefit from cherry locks as they combine security with the convenience of repeated opening for subscribers. Electronics and Gadgets: Sensitive electronics and gadgets can be securely packaged with cherry locks, ensuring the contents are protected during shipping and readily accessible to users. Conclusion Cherry locks in roll end tuck top boxes represent a significant innovation in packaging design, offering the perfect balance between security and ease of access. Understanding the design, features, benefits, and potential applications of cherry locks can help businesses make informed choices when selecting packaging solutions. Whether you are in retail, e-commerce, or any other industry, the integration of cherry locks into RETT boxes can enhance your packaging strategy, providing a secure and user-friendly experience for both businesses and customers alike. If you are interested in roll end tuck top boxes with cherry locks, then partner with Brown Packaging today to get started. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Roll End Tuck Top Facebook Twitter LinkedIn Pinterest Relevant Posts

In e-commerce, packaging plays a crucial role in ensuring that your products reach customers safely and intact. Whether you’re shipping lightweight apparel or heavy electronics, choosing the right corrugated box material is essential for protecting your items throughout the delivery process. Corrugated boxes come in three main types—single-wall, double-wall, and triple-wall—and each offers varying levels of durability and protection. Here’s a breakdown of how to choose the best option for your e-commerce business. Single-Wall Corrugated Boxes: Cost-Effective for Lightweight Items Structure: Single-wall corrugated boxes consist of one layer of fluted material between two layers of linerboard, making them the most common type of corrugated packaging. Best For: Lightweight products such as apparel, books, or small household items that don’t require extensive protection. Benefits: Affordable: Single-wall boxes are cost-effective, making them the most economical choice for businesses shipping light items. Lightweight: Their lightweight nature reduces shipping costs. Widely Available: These boxes are easily sourced and come in a variety of sizes to meet your e-commerce needs. Drawbacks: Limited Protection: While sufficient for lightweight items, single-wall boxes don’t offer much protection for heavy or fragile products. When to Use: Single-wall corrugated boxes are ideal for e-commerce businesses shipping lightweight, durable items that don’t require additional padding or protection during transit. Their low cost and availability make them perfect for high-volume shipping. Double-Wall Corrugated Boxes: Added Protection for Fragile or Heavy Items Structure: Double-wall boxes are made up of two layers of fluted material sandwiched between three sheets of linerboard, offering greater durability and strength than single-wall boxes. Best For: Heavier or more fragile products like kitchen appliances, electronics, or bulkier items. Benefits: Enhanced Durability: With two layers of fluting, these boxes provide superior protection against crushing, drops, or impacts. Perfect for Shipping Fragile Goods: They are ideal for protecting items that require more cushioning during the shipping process. Drawbacks: Heavier: Double-wall boxes are heavier than single-wall, increasing shipping costs slightly. More Expensive: They are costlier than single-wall boxes but provide a better balance of protection and price. When to Use: Double-wall boxes are the best option for e-commerce businesses that ship mid-weight or fragile products. These boxes offer a good balance of protection and cost, ensuring your products arrive intact while maintaining a manageable budget. Triple-Wall Corrugated Boxes: Maximum Protection for Heavy-Duty Shipments Structure: Triple-wall corrugated boxes are built with three layers of fluted material, offering the highest level of strength and durability. Best For: Extremely heavy or high-value items such as industrial equipment, furniture, or large appliances that require maximum protection. Benefits: Ultimate Strength: These boxes are highly resistant to crushing and damage, making them perfect for large or high-value shipments. Ideal for Long-Distance or International Shipping: Triple-wall boxes can withstand rough handling over extended periods, providing peace of mind during long-distance shipping. Drawbacks: Higher Cost: Triple-wall boxes are the most expensive corrugated option due to their enhanced strength and durability. Increased Weight: They are significantly heavier, which can result in higher shipping costs. When to Use: If you’re shipping heavy, valuable, or sensitive products that need the highest level of protection, triple-wall corrugated boxes are the best choice. Though they come at a higher cost, they offer unmatched durability and security during transit. Key Factors to Consider When Choosing the Right Corrugated Box When deciding which corrugated box type is best for your e-commerce packaging, consider the following factors: Product Weight and Fragility: For lightweight, durable items, single-wall boxes are sufficient. For heavier or fragile items, double or triple-wall boxes provide necessary protection. Shipping Distance: Longer shipping distances and international shipments are best handled with double or triple-wall boxes, as they offer better protection against handling damage. Budget: Balancing protection with cost is crucial. While double and triple-wall boxes provide more durability, they are more expensive, so businesses must evaluate the importance of protection versus shipping costs. Conclusion Selecting the right corrugated box material for your e-commerce business is essential for protecting your products and maintaining customer satisfaction. Single-wall boxes are ideal for lighter, non-fragile items, while double-wall and triple-wall boxes offer added protection for heavier or more valuable goods. By considering the weight, fragility, and shipping distance of your products, you can make an informed choice that ensures your items arrive in perfect condition while keeping shipping costs in check. If you’re interested in ecommerce packaging and/or corrugated boxes, then partner with Brown Packaging today to get started. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Ecommerce Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts