Cartons

Packaging Guide
PROCESS SUSTAINABILITY INDUSTRY PACKAGING
INTELLIGENCE DRIVEN FOCUSED SPECIALISTS
 Cartons
Packaging Guide

How Can Allpack Support You 2

Welcome To Allpack 3
Corrugated Manufacturing 4-5
Choosing The Correct Corrugate For Your Needs 6-9
Sustainability Of Corrugated 10-13
Bookwraps 14-15
Pallet Boxes 16-17
Postal Cartons 18-19
Single Wall 20-21
Double Wall 22-23
Bespoke 24-25
Carton Stacking 26
Box Compression Test Explained 27
How To Measure Cartons 28-29
Quick Guide To Generic Fefco’s 30-31
FAQ’s 32-33 01
How Can Allpack
Support Your Business
On-site packaging consultations is something Reduce your carbon footprint
our team is passionate about. It’s rather like
an MOT. We will measure the health of your
packaging process to ensure that it is road Consolidate packaging ranges
worthy and commit to any repairs that need to
take place. Our team are able to assess when
time is lost, excess packaging is being used, if Increase packaging knowledge
shipping costs are too high and how to reduce
your damages.

“At Allpack we have 3 decades

of packaging experience you can
tap into.”

Click me

Contact our team on:

[email protected] to contact us

01543 396 777

Welcome To
Allpack
Allpack is an international packaging manufacturer serving UK & European clients with industry-
leading, recognised brands and products. Currently, the group turnover exceeds £240 million, including
multiple manufacturing sites across UK, Europe and a global portfolio of suppliers our customers can
rely on. We pride ourselves in our manufacturing and sourcing abilities, which results in competitive
pricing across all our product ranges, for the benefit of our customers.

Our 6 UK distribution centres allow us to offer

national distribution coverage for all our customers,
with our Head Office and National Distribution Centre
based in Cannock, in the West Midlands.

We actively invest in maintaining and expanding our

range of industry acknowledged accreditations and
certifications, ISO 14001 / 9001, FSC, Sedex and
BRCGS - Storage and Distribution, to ensure our LEEDS
customers are provided with the highest level of Northern Distribution
service and product quality, whatever is ordered,
wherever they are located.
Norton Canes
Regional Distribution

CANNOCK
National Distribution
Peterborough
TAMWORTH Regional Distribution
Midlands Distribution
LONDON
Southern Distribution 02-03
Allpack’s
European Corrugated
Manufacturing Sites

Key of Locations
UK
France
Germany
Poland
Turkey
Corrugated
Manufacturing

Our Corrugated Manufacturing capacities covers the whole of Europe, with sites based in the UK, France,
Germany, Turkey and Poland.

Having a large portfolio of machinery, such as Latitude Casemakers and Bobst die-cutters to deploy
and utilise to meet our customer’s requirements, is just one way we create a better package for all our
clients.

t
Fac
n
Fu On an average day,
at a single site, based on 4
casemakers running the full 24
hours at 20,000 cartons per hour,
we can produce 1,920,000 cartons
per day. Filling 60 Artic lorries from
just one site and on average across
all sites 180
Artic lorries.

04-05
Choosing The Correct
Corrugate For Your Needs

Depending on what products you are packing, the specification of your carton can vary drastically.
For example, a business packaging dry food goods would need a completely different specification -
not just in size - but in board grade and fluting type, compared to a business needing packaging for
construction products.

The paper type is becoming increasingly important as the demand for sustainable options increases.
Each paper type has different properties, and this can affect what type you’ll need for the products
you’re shipping out.

Kraft (K)
Kraft liner represents the top-grade material in terms of appearance and is usually made up of virgin
fibres.

Test (T3)
Most commonly manufactured from 100% recycled material, and can be recycled/re-used up to 7
times.

Semi Chemical Fluting

Semi-chemical fluting is originally made from hardwood pulp. Due to hardwood trees’ slow growth
period, they have now predominatly been replaced by hyperflute which is chemically treated.

Hyperflute
Hyperflute, is a type of corrugated cardboard that has been chemically treated with a specific
moisture resistant coating.

06-07
Flute Types & What
They’re Used For

Single faced board is generally not used in carton

production, but as a separate product used as
wrapping / voidfill.

Single wall board is predominately used for

packaging lightweight products and perfect for
sending through the post.

Double wall board is better suited for heavier

weighted or higher value items. It has the greatest
protection qualities and can absorb shocks that
may happen in transit.
Paper Weights

Your paper weight and fluting can’t be counted on alone for your carton’s strength performance. There
are multiple factors that would need to be examined to determine what’s the best board grade to
be used. Factors such as multi-depth creases, perforations, how the box is stacked, level of carton
printing, hand holes and the conditions in which the cartons are stored can all adversely affect a
carton’s performance by up to 80%.

Hand Holes Multi Depth Perforations Print Work

Creases

At Allpack we are committed to extensive testing, which may lead to multiple questions when quoting,
such as the weight of the products being enclosed, how high they are to be stacked and your printing
requirements, in order to determine the best possible board grade to be used, for safe and minimal
damages, during transit.

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 Sustainability Of
Corrugated

We focus on providing you more sustainable

options, it’s something as a company we feel very
passionate about. Corrugated packaging is one of
the most sustainable ways to package your goods,
made from renewable and recycled materials and
being the most easy to recycle by end users with
curbside recycling.

Corrugate is also biodegradable - meaning even

if it finishes in landfill it would end up starting
to break down without causing harm. Typically
cardboard cartons can take up to 3 months to fully
biodegrade (within a landfill environment).

Our paper we use in corrugated manufactuing is

sustainably sourced, FSC® approved and comes
from either softwood trees or recycled fibres. Using
softwood trees are the best choice to use for paper
making, as they are much quicker to replant and
grow than hardwood.
 Sustainability Of
Corrugated
Carbon Footprint
From cradle to grave the carbon footprint of a box based on 1Kg of
manufactured product is 0.94kg CO2. From our in-house sustainability
specialists, calculations show that per Kilo produced of card, 0.950Kg
CO2 is produced. At Allpack we use Kraft paper which takes 0.455
Per Kg to produce. In comparison our product at Allpack has half the
carbon footprint of a conventional carton, helping to save energy
during manufacture and reduce the amount of CO2 released into the
environment.

A common e-commerce box that is 23 x 23 x 23 cm is estimated to emit

0.27Kg CO2, which is the equivalent of 25.2g of Diesel.

Other varying factors such as the fluting used and print surfaces also
contribute to the overall environmental impact of a cardboard box.

Box Dimensions (cm) Box Weight (Lbs) Box Weight (Kg) Kg CO2 / box

15 x 15 x 15 0.28 0.127 0.12

23 x 23 x 23 0.64 0.291 0.27

30 x 30 x 30 1.08 0.49 0.46

41 x 41 x 41 1.88 0.854 0.80

61 x 61 x 61 4.2 1.907 1.79

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 Sustainable
Corrugated
Packaging
Solutions

12-13

Next Day Delivery Wide Product Range FSC® Accreditated Products

: www.allpack.uk.com *[email protected] ( 01543 396 700
 Bookwraps

BoxwrapTM is an eco-friendly, efficient postal packaging solution.

BoxwrapTM is an innovative new method for mailing objects of varying

heights and weights, such as books or semi-fragile items. Anything that
can fit through a letterbox can be packaged using our bookwrap product -
BoxwrapTM.

Made from FSC® approved, sustainably sourced recycled paper and being
fully recyclable for the end user, BoxwrapTM is the best eco-friendly choice
for letterbox postal packaging. With an ultra-strong permanent, tamper
evident seal it provides security to your parcel and means no extra tape is
required.

BoxwrapTM is constructed from high-strength corrugated board and has

been tested to show burst resistance, resulting in it’s great effectiveness
of protection of the goods inside.

Available in 3 standard sizes, each when full meets the Royal Mail small
parcel criteria, giving you peace of mind that your postal transport will give
you cost savings.
Click me
Bespoke sizes & printed options are available, being able to promote your
brand whilst safely transporting your goods.
to visit our
Boxwrap™
range

14-15

Next Day Delivery Wide Product Range FSC® Accreditated Products

: www.allpack.uk.com *[email protected] ( 01543 396 700
 Pallet Boxes

Our DuraboxTM Pallet Boxes are the ideal choice for the storage and
transport of heavy goods. They are delivered flat-packed for optimum
space-saving, and can be assembled in seconds, ensuring efficiency in
your warehouse packing operations.

Available in Standard and Euro size footprints, with the option to have a
perforated drop-down panel for ease of access to the products stored
inside and heat-treated versions are available.

As a set, DuraboxTM Pallet Boxes can be either caps and sleeves that work
together to provide a snug fit, or alternatively we have a range of 0200s
that can come with or without the pallets attached. DuraboxTM Pallet
Boxes are a strong and secure corrugated structure to safely transport
heavy goods.

Made up of FSC® approved and sustainably sourced heavy duty

corrugated board, these DuraboxTM Pallet Boxes are the best eco-friendly
choice for warehouse packaging solutions – being 100% recyclable and
can even be re-usable dependant on the products stored inside.

Click me

to visit our
pallet box
range

16-17

Next Day Delivery Wide Product Range FSC® Accreditated Products

: www.allpack.uk.com *[email protected] ( 01543 396 700
 Postal Cartons

The DuraboxTM Postal Carton is a high-quality single wall

packaging solution specifically tailored towards E-commerce
businesses, with multiple sizes available.

The DuraboxTM Postal Carton is an innovative product that’s

manufactured to safely and securely house a range of
products that are to be sent via courier from E-commerce
businesses. Its lightweight design is one of the best solutions
for your business, it’s not only cost effective, but it’s perfectly
suited to packing, storing and shipping products.

Made from FSC® approved single wall corrugate and being

fully recycled via curbside solutions, the DuraboxTM Postal
Cartons are a great eco-friendly choice that also enhances
end-user satisfaction.

Featuring a strong tamper evident seal, not only does it Click me

provide a secure close, but it means your products will reach
your end user without being tampered with during transit.
This peel and seal feature also means no extra tape is
to visit our
required, cutting down on your packaging costs. Postal Carton
range

18-19

Next Day Delivery Wide Product Range FSC® Accreditated Products

: www.allpack.uk.com *[email protected] ( 01543 396 700
 Single Wall Cartons

Our range of single wall cartons - The OxboxTM, is a range

specifically designed to outperform double wall boxes.

The OxboxTM range in comparision to traditional double wall

cartons is 7% lighter weight, meaning less stress on your
operations team, saving up to 40% in storage capabilites,
giving your warehouse extra space for other products, or to
have extra stock of this stocked carton range.

Our Oxbox™ range has been designed to offer increased

carton strength, coupled with a reduction in carbon
emissions during manufacture. Oxbox™ cartons have
been specially manufactured to help reduce your carbon
footprint, with Oxbox™ cartons manufactured using 30%
less CO2.

“Save space, save the Click me

environment!”
to visit our
Oxbox™
range

20-21

Next Day Delivery Wide Product Range FSC® Accreditated Products

: www.allpack.uk.com *[email protected] ( 01543 396 700
 Double Wall Cartons

Our DuraboxTM range is our most extensive double wall carton

brand. DuraboxTM has a comprehensive range of sizes with
multi-depth creases enabling you to use one box for multiple
sizes. 1 Pallet
= 150 Boxes
DuraboxTM is 100% recyclable, FSC® certified and the
fluting used is specifically tailored to out perform standard
double wall boxes. The DuraboxTM range uses ‘EB’ fluting,
using these two flutes together creates not only a slimmer
profile, resulting in 40% extra storage, but also a denser
more compact carton that can withstand higher volumes of
weight.

1 Pallet
= 90 Boxes

Click me

to visit our
Durabox™
range

22-23

Next Day Delivery Wide Product Range FSC® Accreditated Products

: www.allpack.uk.com *[email protected] ( 01543 396 700
 Bespoke Cartons

We are design specialists, we will customise your packaging

to help improve your brand appearance and properly protect
your product in transit, with products that are developed in Click me
our state-of-the-art packaging design suite.

We understand the science of packaging and how best

to integrate into your processes to enable optimum
efficiency for your operations. From optimising products to see our
CAD sample
and machines, to proposing new design concepts; CAD & production
3D concept stage to printed samples and final production,
we work in partnership with you to achieve your packaging
goals.

24-25

Next Day Delivery Wide Product Range FSC® Accreditated Products

Box Stacking
Performace

The way how your cartons are stacked will result in a varying strength of stability and how the cartons
peform.

Although brick stacking may seem like the best possible stack palletisation for stability, this method
of stacking can actually cause a loss of carton strength of 40 - 60%. In comparison to column stacking
which results in a 0% loss of carton strength.

In terms of stacking on a pallet the most commonly used, depending on the height of the
stack, is utilising both column and brick stacking for the ulitmate stability and carton
strength. Trapping column stacked cartons inbetween brick stacked as shown in the
image to the right, creates a stable pallet stack whilst evenly distributing the stress points
of the cartons, to help reduce in transit damages.

Choosing the right pallet box stacking style

depends on various factors, including the
type of products you handle, available
storage space, and accessibility needs. Brick
Understanding the advantages and best-
use scenarios of each stacking style allows
you to make informed decisions that can Column
improve warehouse efficiency and product
safety. Whether you opt for block stacking, Brick
column stacking, cross-stacking, honeycomb
stacking, or single deep racking, your choice
should align with your specific logistics and Pallet
storage requirements.
Box Compression
Test

A Box Compression Test can estimate the stacking

strength of your boxes, cartons and containers. It
will also determine the forces that your packaging
can withstand during transportation. When
conducted it can give you a clear idea of how your
packaging will respond under pressure and if the
product within can remain safe and damage free.
Once the effectiveness of your current box has
been ascertained, we can advise you on the correct
box or carton grade, meaning you can ensure your
boxes aren’t over-engineered, resulting in wasted
material.

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How To Measure A
Generic 0201

To calculate the measurements of a generic 0201 case all you need is length x width x height. This
format will also be what you use to explain what carton you need to our Sales Team - this format
is also used by our manufacturing team when they are configuring the machines to create the size
carton you require.

To get these measurements the length is the longest side, width the shortest and the height is the
side that is perpendicular to the sides you used to measure the length and width. See the diagram
on the opposite page for a more visual representation of these measurements.

For example if a carton was 200mm long by 150mm wide and had a height of 100mm, the
measurement would be written down as 200mm x 150mm x 100mm - this way you know that our
Sales Team have the correct dimensions in the correct order, to help create your quote. If ever
you’re unsure our Sales Team will assess samples and we’ll conduct an in-house like-for-like
comparison - along with producing Allpack samples for you to test and make sure the carton is up
to the standards you need.

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0200 0201 0203

0215 0422 0426

0427 0711 0713

Basic Guide to
Fefcos

Fefco codes are the internationally recognised system for the clarification of corrugated
carton designs. With Fefco codes it makes the initial coversations between customer and
business more effective as there is a common system to help explain their requirements in
regards to carton styles.

Please see page opposite for the most generic Fefco styles you will usually come across.
The Allpack Team are fully integrated with Fefco styles and combined with our dedicated
CAD Team bespoke cartons can be made specifially for our clients.

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Frequently
Asked Questions

How long does it take for products to biodegrade?

European standards suggest that for anything to be biodegradable, 90% of it must break down into
2mm pieces within 6 months.

Would paper products cause deforestation?

Paper production is not responsible for deforestation, as rain forest trees are typically hardwood
and slow growing. Softwood timber is fast growing, but the paper industry generally uses offcuts
and trimmings used in manufacture of furniture and timber production. The unwanted wood is
transformed into wood chips and then used as pulp, for paper production.

Are your boxes made from recycled material?

Yes, our production uses FSC® certified board, made using up to 100% recycled paper, which has
been sustainably sourced.

Contact us on 01543 396777 or email [email protected]

to discuss your packaging solutions in more detail
 Recyclable Material Factsheet

Made from
Type renewable material
Biodegradable Recyclable Compostable Product examples

Wood YES YES NO YES Pallets, crates

Cardboard YES YES YES NO Boxes, bookwraps

Paper YES YES YES NO Tape, voidfill, roll, bags

Polypropylene NO NO YES NO Tape, strapping

Polystyrene NO NO YES NO Voidfill

Polythene NO NO YES NO Bags, shrink wrap

Polyester NO NO YES NO Strapping

Learn more about what can be recycled at:

www.allpack.uk.com/sustainable-packaging

32-33
 Cartons
Packaging Guide

Somerville House | Blakeney Way | Kingswood Lakeside | Cannock | WS11 8LD

01543 396777 www.allpack.uk.com