I CAN'T FIND THE ITEM I'M LOOKING FOR. HOW CAN I SEARCH FOR IT?
Try entering a keyword, phrase, or item number into the Search box at the top right of the homepage. Of course, there's always a chance that what you're looking for is not in our store right now. That is what the custom page is for.
I HAVE SEEN A PRODUCT THAT I LIKE BUT I WANT IT CUSTOMIZED. WHAT’S THE BEST WAY TO GET WHAT I WANT?
Every item on our store can be customized. All you have to do is click the "GO CUSTOM" button on the item order page and tell us what you need. You can also contact us at (800) 410-8390 or get your project started by sending an email to firstname.lastname@example.org. Customization can be as simple as a size modification or a complete design development project.
HOW DOES THE CUSTOM DESIGN PROCESS WORK?
First, we will need to complete a structural design based on your requirements. If you are going to print on the box, we'll provide an electronic die line (blueprint) of the box so you can lay out your artwork. If you need assistance with graphic design, we can assist you for a nominal fee. Once we receive the completed die line back from you with artwork, we will produce your boxes in one to two weeks.
WHAT IS YOUR CUSTOM DESIGN FEE?
At Box+Foam, we don’t charge for designs. We may ask for a $250 deposit if the design is complicated. But that deposit is completely refunded when you place an order. Simple designs, such as sizing a box or foam pad, do not require a deposit.
WHAT IS TOOLING?
Unlike traditional shipping containers, die cut boxes require special tooling (often called a cutting die) to stamp out the box from a blank sheet of material. Although there is a one-time cost involved, many styles and shapes of packaging can't be manufactured without tooling. Tooling prices are based on the size and complexity of your package, and we will provide firm quotes prior to making your boxes.
DO YOU HAVE EXISTING CUTTING DIES THAT I CAN USE FOR MY ORDER?
Yes. We have a variety of styles and sizes to choose from. Although we do not publish a list of stock dies, your customer service representative will be happy to try and locate an existing die that closely matches your requirements.
CAN I GET A SAMPLE?
In most cases, you will receive a sample to approve prior to us running your die cut order. If you would like a sample before placing an order, we can make one or more for a nominal fee.
CAN MY COMPANY LOGO BE PRINTED ON MY BOXES?
Yes, and we also have multi-color printing capabilities.
WHAT COLORS CAN YOU PRINT?
We can print just about any color. Custom colors have an extra ink charge of $125 - $200.
CAN YOU DESIGN MY ARTWORK FOR ME?
We rely on you, the customer, to provide us with the artwork that you would like to use on your packaging. The artwork needs to be supplied in a vector-formatted file.
CAN I PICK-UP MY ORDER AT YOUR LOCATION?
Yes, you can. We will call or e-mail you when it is ready.
WHAT IS THE DIFFERENCE BETWEEN CORRUGATED AND CARDBOARD?
The term “cardboard box” will often make those within our industry cringe. Though it is a common misnomer, a “cardboard box” is technically known as a corrugated fiberboard carton. True “cardboard” boxes (a.k.a. chipboard) would hold a lightweight product, such as cereal or a board game. Corrugated fiberboard is utilized in retail packaging, shipping cartons, product displays, and any other application requiring a lightweight but sturdy material.
WHAT IS SINGLEWALL MATERIAL?
This is the most popular corrugation material used in the boxes we manufacture, it consists of only one layer of whichever type of flute you pick. It is available in a wide range of board strengths, from 23 ECT right throough to 44 ECT. Generally, depending on what type of flute you have chosen, this type of wall structure is not the best choice for shipping heavy objects.
WHAT IS DOUBLEWALL MATERIAL?
This wall structure is made of one layer of “B” Flute and one layer of “C” Flute. Stronger than a single wall structure, double wall enables heavier objects to be shipped and should be used when a stronger box or extra padding is needed. Double wall is available in 48 ECT to 71 ECT and is excellent for stacking heavier items.
WHAT DOES "FLUTE" MEAN?
The "flute" describes the structure of the wave shaped cardboard material that makes up a board. The types are:
B-Flute - The second flute size adopted by the corrugated industry, has lower arch heights than A and more flutes per foot (50). This means that the medium contacts and supports the liners at a greater number of points, providing a stiff, flat surface for high quality printing and die cutting and with excellent crush resistant properties. B-Flute is also preferred for high speed, automatic packing lines and for pads, dividers, partitions and other forms of inner packing. Complex die cuts and beverage trays are excellent applications for B-Flute as are can cases, wrap-around blanks, glass-to-glass packs and slip sheets. B-Flute is generally combined with light weight liners but can be used with heavier facings if the need arises. This is a cross-section profile of the basic types of flutes.
C-Flute - C-Flute came along next to split the difference between A and B Flutes. With 42 flutes per foot, it's thinner than A-flute, thicker than B, and offers good cushioning, stacking and printing properties. C-Flute is by far the most widely used flute size. An estimated 80% of today's corrugated containers are made of C-Flute board.
E-Flute - E-Flute has the greatest number of flutes per foot at 94 which gives it the greatest crush resistance and the flattest surface for high quality printing applications. The thin board profile of E-Flute (it is one-fourth the thickness of C-Flute) reduces box size and saves storage space. Because of its thin profile and excellent cushioning properties, E-Flute can often substitute for conventional folding cartons or solid fiber containers. Examples of E-Flute applications include boxes for cosmetics, fragile glass and ceramic items and delicate instruments. Another growing end-use is for pizza boxes where the retailer wants a cost effective container with good graphics and excellent product protection.
WHAT IS A BOX MAKERS CERTIFICATE (BMC)?
On the outside of one of the bottom flaps will appear a label called the Box Maker's Certificate. This mark is the maker's certification as to the strength of the box and its materials. Comparing these numbers helps you pick the appropriate box for the specific job. Below is a sample certificate for a simple carton:
Burst Test - The force required to rupture the board using vacuum pressure. This relates to the box's ability to withstand forces, and therefore to contain and protect the contents during rough handling.
Combined Weight on Facings - This is a measure of the weight the side of the box can withstand when something is placed on top of the box. This relates to the stackability of the box.
Size Limit - This is the maximum length in inches that a sheet of this board can be while still maintaining its strength characteristics.
Gross WeightLimit - This is probably the most important measure. This tells us the maximum total weight of contents that can be safely placed in the box.
WHAT IS "POLYURETHANE" FOAM?
Polyurethane foam refers to a number of different types of foam consisting of polymers made of molecular chains bound together by urethane links. It can be flexible or rigid, but has a low density. Flexible polyurethane foam is most often used in bedding and upholstery, while the more rigid variety is used for thermal insulation and in automobile dashboards.
Flexible polyurethane is made in blocks and then cut to its desired shape. This is the way in which furniture cushions are made, for instance. Some materials can substitute for this application of polyurethane foam, such as polyester fiber or steel springs. However, polyester fiber does not recover nearly as well as foam does after compression. Steel springs recover well, but can become noisy as they get worn out. They also require some form of cushioning between them and the user.
In addition to the flexible and rigid types, semi-flexible polyurethane foam also exists, and is used extensively in automobile interiors. Seats, armrests, and headrests are frequently made from the semi-flexible variety of this material. In the case of seats, the polyurethane foam is formed in a mold, and then removed and upholstered.
WHAT IS YOUR MINIMUM ORDER SIZE?
Our minimum order size is 1. Just keep in mind that all set-up charges are spread out over the quantity of the order. So if the set-up is $100 and you order 1 box then $100 is added to the price of the box. If you order 100 boxes then only $1 is added to the cost of each box.
WHY DO SHORT RUNS COST SO MUCH MORE THAN LONGER RUNS?
Each process to produce a finished package requires setting up machines. These setups are required to ready the machinery to produce each component of the packaging. Score wheels need to be set. Slots are positioned. Dies are attached to the press. Plates are mounted to the printing station. Each setup also requires additional material to be run through the machine that generally becomes scrap or collateral of the initial run. All of this requires additional labor and material.
HOW CAN I REDUCE MY COSTS ON SHORT RUNS?
At Box+Foam we have equipment to assist with short runs and we also have the ability to design your package for shorter runs. Many of our machines are equipped with computer-aided setup. We will buy equipment and then toss out the original computer and install one that works for us. That way we can design the software and install some of our better ideas into the machine. For example, our two color printer can now be set up for printing another job while it's running. The same machine will hold over a thousand jobs in its memory that will allow us to simply add a code and be on to the next order. We also have a machine that is strictly made for small orders and sets itself up through a software program that we wrote. There is give and take for more complicated orders, however. If you are realistic about your run quantities, we are happy to assist you with packaging designs that can be run economically.
HOW DO I MEASURE A BOX?
Box sizes are measured by using inner dimensions unless otherwise specified. Dimensions are based on the opening of an assembled box. Looking at the opening, the longer of the two sides is considered the "length." The shorter of the two sides is the "width." The side perpendicular to the length and width is the "depth" of the box.
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