Lining Interior Boxes
Mounting paper to the board prior to production creating a full liner to the inside of the box. This makes for a higher-end package as it fully covers the chipboard. Paper used varies from specialty papers in solid colors and textures to commercially printed graphics. It’s used for enhancing package presentation as well as extended marketing and branding.
Pre-Production Die-Cut
Board and paper are die cut prior to manufacturing. Pre-production die cut method is used to implement sophisticated, die cut shapes and/or transparent windows on the top of the box to reveal or show-case product inside. There is typically 1/32” to 1/16” paper overlap to prevent board from being exposed on the exterior of the box. This method is also used to create unique dimensional looks like angle cuts for a sloped box or panel notches.
Die Cut With or Without Clear Acetate Window
Sloped
Post-Production Die Cut
The finished box is die cut after production using either custom punch presses or automatic thumb-notch machines. This provides a flush cut in which there is no paper overlap. This method is used for similar purpose and applications as the pre-production die cut method but limited to more conventional die cut shapes and panel notches. Most commonly used in die cut window boxes in which KPB glues in a full piece of transparent vinyl to the inside of the box.
Die Cut With or Without Clear Acetate Window
Thumbcut
Wrapped Wide V-Notches
This is a special panel cut using the pre-production die cut method in which the finished result provides for a completely wrapped wide v-angle shaped notch located on box depth panels. It gives a more finished look and added dimension. Commonly used on clamshells for ease of opening as well as slipcases allowing for easier removal of books or DVDs. This approach is limited to a certain angle.
Inserts
Rigid chipboard – typically out of black chip or white vat board. Constructed as open corner or stayed (formed with stay tape applied to all four corners). Post-production die cuts can be added. KPB offers a complete turn-key approach to your rigid box packaging needs to include custom inserts used to present and stabilize the product. Inserts can also be designed as platforms, spacers, and dividers.
Inserts can be constructed from the following material:
- SBS folding carton sleeve – full or partial (aka belly band)
- Fully tight wrapped, inverted rigid tray – plain white or printed. Post-production die cuts conformed to your product or products.
- Foam – Polyurethane ether or ester. Typically charcoal grey. Simple pad, die cut, and/or sculpted precisely to your product
- Vacuum formed trays – with or without flocking
SBS Folding Carton Insert – Plain White or Printed
SBS Folding Carton Sleeve
Fully tight wrapped, inverted rigid tray – plain white or printed. Post-production die cuts conformed to your product or products.
Foam – Polyurethane ether or ester. Typically charcoal grey. Simple pad, die cut, and/or sculpted precisely to your product.
Simple Fulfillment
- Product placement into rigid box packaging. This is limited to certain products such as books, journals, and marketing materials
- Assembling inserts and placing into rigid box packaging
- Bar coded corrugated case labels available
Supplier Managed Inventory
Supplier managed inventory available for qualifying customers with large format box programs. KPB custom designs inventory databases specific to your box program needs from raw materials to warehousing.
Ready to get started?Request a Quote!