One Panel, Five Panel & Vari-Depth Folders
Custom Corrugated Folders
Custom corrugated folders are versatile packaging solutions that can be tailored to fit a wide range of products. With multiple panels and depth options available, they offer flexibility for packaging items of varying sizes and shapes. These folders can also be customized with printing and graphics to enhance branding and marketing efforts.
One Panel, Five Panel & Vari-Depth Folders
Custom Corrugated Folders
Custom corrugated folders are versatile packaging solutions that can be tailored to fit a wide range of products. With multiple panels and depth options available, they offer flexibility for packaging items of varying sizes and shapes. These folders can also be customized with printing and graphics to enhance branding and marketing efforts.
What is a Corrugated Folder?
Corrugated folders, also known as document folders, are a type of corrugated box designed to store and transport flat documents or materials. They are typically constructed with two or more panels, with one panel serving as the bottom and the others forming the sides and the top of the box. Folders often come with locking tabs, tuck flaps or other closures to keep the contents secure during transport or storage. They are commonly used in offices, archives, and libraries to store and organize documents, as well as for mailing or shipping flat items.
A one-panel (OPF) folder is a single layer of corrugated, which is folded into a rectangular shape. It is commonly used to package flat and thin items such as pictures, books, documents, mailing or storing documents, as it can be easily sealed and provides adequate protection.
A 5-panel (5PF) folder is a type of corrugated box that has five panels hinged together, with the fifth panel overlapping the first panel. The box can be easily assembled by folding the five panels into the desired shape, and it is commonly used for packaging long or narrow items.
Vari-depth (VDF) folder is a type of corrugated folder that comes with a series of pre-scored creases, allowing it to fold down to create a custom depth. This feature enables this type of folder to adapt to varying sizes and shapes of items, making it a versatile option for packing and shipping needs.
Corrugated Folder Options and Features
Choose from a variety of print options, finishes, and shapes to create a corrugated box that is uniquely yours. With a range of material thickness options, you can create boxes that are lightweight and durable. Graphic design services are available.
Print Options
Flexography (also known as flexo) is a printing process that uses flexible relief plates made of rubber or photopolymer to transfer ink onto various substrates, such as corrugated, plastic films, and paper. It is a high-speed, cost-effective printing method that is suitable for printing on rough, porous, and irregular surfaces.
Digital print refers to a printing method that uses digital files such as PDFs, JPEGs, or TIFFs as a source for printing images or text. Digital print technology has revolutionized the printing industry by offering faster turnaround times, lower production costs, and the ability to produce high-quality prints
Lithography is a printing technique that uses a flat printing plate, a special kind of ink, and oil-based or water-based liquids to transfer an image onto a substrate. It produces high-quality, sharp and clear prints that are suitable for printing high-resolution graphics and text.
Graphic Design
Graphic design must reflect the brand identity and effectively communicate the brand’s message to customers.
Maximize product visibility by apply graphics with contrasting colors, bold text, and high-quality images.
The text used in the graphic design must be legible, both from a distance and close up. The font size, color, and style must be carefully selected to ensure that the text is easily readable
Have your graphics effectively utilize the space available on the display, including the sides and back, to maximize impact and exposure to the product.
Display relevant product information, such as product name, benefits, and features. This information should be presented in a clear and concise manner.
Create a design consistent with the brand’s overall design and marketing materials, ensuring a cohesive look and feel across all channels.
Flexible designing, allowing for the display to be easily updated as needed, without requiring a complete redesign.
View your product with a realistic 3-D rendering that is easily sharable. Renderings are ideal for reviewing display prototypes and enabling quick and cost effective edits and changes.
Finishes
A gloss finish is a shiny and reflective surface that is achieved by applying a gloss varnish over the printed surface. This finish enhances the vibrancy and saturation of the colors and makes the printed graphics appear more eye-catching.
A matte finish is a non-glossy surface that has a flat and velvety texture. This finish provides a subtle and sophisticated look and reduces glare, making it ideal for printing products that require a professional look.
Spot UV is a printing technique that involves printing a clear UV varnish in specific areas of the printed surface to create a glossy texture on specific parts of the design. This finish adds depth and texture to the printed graphics and enhances the overall appearance of the product.
Embossing is a printing technique that involves creating a raised or recessed design on the printed surface by pressing a metal or plastic plate onto the surface. This finish creates a tactile experience for the consumer and adds dimension to the printed graphics.
Foil stamping is a printing technique that involves applying a thin layer of metallic or colored foil onto the printed surface. This finish adds a metallic shine to the printed graphics and creates a luxurious and eye-catching effect.
Litho lamination is a finishing process that involves bonding a printed piece to a thick layer of paper, plastic or film. This finish provides extra protection to the printed surface, makes the product more durable, and enhances the overall quality of the product.
There are many other finishes we can apply to your custom display such as a varnish, die-cutting, perforation, scoring, film lamination, creasing, hot foil stamping, blind embossing and others.
Strength & Thickness
Single wall corrugated material is the thinnest option, typically ranging from 200 to 500 microns in thickness. This option is suitable for lightweight products and provides a cost-effective solution for boxes.
Double wall corrugated material is thicker than single wall and typically ranges from 600 to 1000 microns in thickness. This option provides additional strength and stability to the box and is suitable for heavier products.
Triple wall corrugated material is the thickest option, typically ranging from 1000 to 1500 microns in thickness. This option provides maximum strength and stability to the box and is suitable for very heavy products.
The most common ECT (Edge Crush Test) rating for custom corrugated boxes is typically between 32 and 44. ECT is a measure of a box’s strength and its ability to resist crushing under pressure, which is an important factor in determining the durability and protection of the packaged product during shipping and handling.
Burst ratings for corrugated boxes range from 200 to 400, with higher numbers indicating greater strength and durability. A burst rating of 200 is suitable for lightweight products, while a burst rating of 400 is recommended for heavier products.
Panel Folder Structural Design
Structural design is a crucial aspect of corrugated boxes, as it affects the stability, strength, and overall appearance of the box. The following are key considerations for structural design in corrugated boxes:
Strength and Durability
A strong and durable corrugated box is vital for protecting products during handling and transportation. This requires careful consideration of factors such as material quality, size, flap and joint design, and the ability to withstand stacking and compression forces.
Size and Shape
The size and shape of a corrugated box are crucial for its strength, durability, and performance. It must be designed to support the product weight, resist compression forces, and allow for easy handling and transportation while ensuring material and production efficiency.
Cushioning and Protection
The cushioning material inside the corrugated box is a critical factor in its structural design as it must absorb shock and prevent product movement during transportation. The type, thickness, and placement of cushioning material are important considerations in ensuring optimal product protection.
Production Efficiency
Custom corrugated box design should optimize for efficient production, including ease of assembly, minimal waste, and reduced production time. Factors such as the use of efficient production techniques and the design of the flaps and joints can enhance the production efficiency of the design.
Sustainability
Sustainability is becoming an increasingly important factor in corrugated box structural design. Eco-friendly materials and designs are considered, with the use of recycled materials, eco-friendly coatings, and efficient production techniques being vital in reducing the environmental impact of the design.
Special Features
Custom corrugated boxes can be designed with special features, like handles or specialized openings, to meet the specific needs of certain products. These features are essential for protecting fragile or heavy items and ensuring easy access to the product.
Interested In Custom Panel Folders?
Frequently Asked Questions
Yes, we do offer recyclable and other sustainable materials. Contact us and we can go over sustainable options with you that best fit your project.
Order minimums vary from project to project, it usually depends on the type of packaging, design, size and desired materials. Contact us and we will evaluate the best options for your packaging needs.
Lead times can vary depending on your display style, design, quantity, materials and other factors. To get an accurate lead time for your project, contact us and a packaging expert will assist you.
Alternatives to Panel Folders, include HSC, RSC, STE, RTE, RETT, FOL and many others. Visit our corrugated box page to view all styles.
Shipping is free to all Southern California businesses. Fees are generally added to orders outside of Southern California or if you need a rush order.
Yes, we have the most common and standard sizes boxes for sale. Contact us to see whether your desired size is available in standard or custom.
