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Folding boxes
Mach mehr aus deiner Produktverpackung – mit unseren hochwertigen Faltschachteln nach Maß, Made in Germany! Ob Kosmetik, Medizinprodukte oder Lebensmittel: Unsere Faltschachteln überzeugen durch höchste Fertigungsqualität, perfekte Passform und brillantem Digital- oder Offsetdruck. Wähle aus zahlreichen Schachteltypen und definiere Größe, Material und Druck ganz individuell – einfach online. So wird deine Verpackung zum Markenbotschafter am Point of Sale!
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Carry handle box
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Highest cardboard quality
Materials for folding boxes
Chrome carton
Cellulose cardboard
Recycled cardboard
GC1 chrome cardboard
Grammage 215, 275, 325, 350 g/m²
White outside, natural colour inside
Smooth on the outside, rough on the inside / natural
Application for food, pharmaceuticals and cosmetics
Highly rigid & tear-resistant
Fresh fibre cardboard from sustainable forestry
Recyclable via waste paper
GC2 chrome cardboard
Grammage 280, 330 g/m²
White outside, white inside
Smooth on the outside, rough on the inside / natural
Application for food, pharmaceuticals and cosmetics
Fresh fibre cardboard from sustainable forestry
Recyclable via waste paper
Chrome cardboard with barrier
Grammage 300 g/m²
White outside, white inside
Smooth on the outside, rough on the inside / natural
Application for food, pharmaceuticals and cosmetics
Highly rigid & tear-resistant
Fresh fibre cardboard from sustainable forestry
Recyclable via waste paper
GZ pulp cardboard
Grammage 350, 450, 500 g/m²
Bright white outside, bright white inside
Smooth outside, smooth inside
Application for food, pharmaceuticals and cosmetics
Highly rigid & tear-resistant
Fresh fibre cardboard from sustainable forestry
Recyclable via waste paper
GZ pulpboard Invercote
Grammage 280, 330 g/m²
Bright white outside, bright white inside
Smooth outside, smooth inside
Application for food, pharmaceuticals and cosmetics
Highly rigid & tear-resistant
Fresh fibre cardboard from sustainable forestry
Recyclable via waste paper
GD2 Recyclingkarton
Grammage 320, 400 g/m²
White on outside, grey inside
Smooth on the outside, rough on the inside / natural
Use as secondary packaging
Made from 80% secondary fibre materials
Recyclable via waste paper
Grass cardboard
Grammage 350 g/m²
Grass look outside, grass look inside
Rough exterior / natural, rough interior / natural
Use as secondary packaging
Made from 70% secondary fibres and 30% grass
Recyclable via waste paper
Natural brown cardboard
Grammage 400 g/m²
Brown outside, brown inside
Rough exterior / natural, rough interior / natural
Use as secondary packaging
Made from 100% secondary fibres (PIW & PCW)
Recyclable via waste paper
Natural cardboard, black
Grammage 350 g/m²
Black on the outside, black on the inside
Rough exterior / natural, rough interior / natural
Use as secondary packaging
Made from 100% secondary fibres (PIW & PCW)
Recyclable via waste paper
Configure folding boxes
Design unique folding boxes
Wide range of materials
Our folding boxes are available in grammages ranging from 215 g/m² to 500 g/m². This means you can find the right material for every product – from lightweight to extra sturdy.
State-of-the-art printing technology
Our folding boxes are produced using digital or offset printing – for brilliant colours, razor-sharp details and packaging that perfectly showcases your brand.
Elegant surfaces
Give your folding boxes a sophisticated feel and high-quality appearance with matt, glossy or soft-touch foil laminate.
Special colours & Pantone
On request, we can print your folding boxes with special colours such as Pantone. This allows you to achieve consistent branding and strong brand recognition.
Window punching
Our folding boxes are available with window cut-outs on request – with or without window backing. This keeps your product visible and inspires additional confidence.
Hot foil stamping
Hot foil finishing gives your folding boxes an exclusive, premium look. Metallic effects attract attention and enhance your brand image.
Embossing and debossing
Our folding boxes can be finished with raised or recessed embossing. This creates tactile textures that enhance your design and create an exclusive brand image.
Recycling
Depending on the selection, our folding boxes are made from fresh or secondary fibres. All cardboard packaging is recyclable via waste paper, thus contributing to a sustainable material cycle.
Nils Harder
CEO & folding box specialist
Your folding boxes are our passion!
Would you like to have your folding boxes professionally produced? Our team will personally assist you with all questions relating to design, materials, finishing and printing, and will work with you to find the right solution. We will reliably accompany you from the initial idea to the finished box and ensure that your product is perfectly protected and your brand is presented in a compelling manner. Feel free to get in touch – we look forward to hearing from you!
Tel.: +49 (0) 751 951 440 0
Mail: [email protected]
>4000 CUSTOMERS PLACE THEIR TRUST IN US
Turn your folding boxes into an experience!
Are you looking for folding boxes that perfectly match your product? We'll take care of it – no matter whether small, large or particularly demanding. We have been producing customised packaging solutions in Germany for three generations, combining experience with modern printing and manufacturing technology. You get quality you can rely on and a team that thinks ahead. Together, we turn your idea into the perfect folding carton – functional, high-quality and distinctive.
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INTERESTING FACTS
Folding box guide
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We would be delighted if you could send us a message and give us an insight into your requirements. The more specific your information is, the better we can advise you and suggest a suitable solution.
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Folding boxes directly FROM THE MANUFACTURER
Your partner for customised folding boxes
What is a folding box?
Folding boxes are product packaging made of cardboard, whose properties meet all the requirements of modern packaging. In addition to conveying information, they also impress with their functionality, stackability, flexible packaging sizes and sustainability. They protect products during transport and can be delivered and stored in a space-saving manner before being assembled and filled.
With a choice of different types of cardboard, finishes and designs, cardboard sales packaging is indispensable for brand image and supports product branding. The wide selection of folding box types, shapes and materials, as well as the diverse design options, make folding boxes a universally applicable form of packaging that is used in almost every industry.
Folding boxes – versatile packaging for your products!
Folding boxes fulfil many tasks: they provide good protection for products, simplify transport and ensure the quality of goods. The packaging looks high-quality, conveys a sense of security and is easy to open and reseal. In addition, creatively designed folding boxes offer great advertising potential – thanks to their excellent printability, information on folding boxes is particularly visually appealing. They convey product features and values like no other packaging and form a representative unit with the product at the POS as well as in online retail.
A folding box must have many characteristics in order to succeed in retail and online sales:
- Attractive brand design
- Attractive brand design
- Product protection
- Quality assurance
- Equipment with barcodes, labels, etc.
- Standard dimensions for shelves and transport
- Safe handling
- Recyclability
At packaging warehouse, you will find folding boxes that can be tailored precisely to your products thanks to the materials used and the different variants available. Whether you need a folding box with hinged lid, Gable boxes, counter displays and carry-handle boxes, or cardboard sheets, inlays and pillow boxes – whether you need security flaps, insert flaps, tuck-in bottoms or automatic bottoms. We have the right folding boxes for you and your products.
The construction of folding box cartons
The material forms the basis for the properties and associated versatility of cardboard packaging. Cardboard types that are suitable for the production of folding boxes are referred to as ‘folding carton board’ – in most cases with a basis weight (grammage) of around 150 g/m² to 600 g/m². The cardboard consists of several layers of fibre material made from fresh fibres from cellulose pulp or recycled fibres:
- Top side (top layer of the box)
- Interlayer + insert (one or more fibre layers)
- Back (back cover of the box)
It is not individual aspects of the fibres used that are decisive for the quality of the cardboard, but rather a balanced ratio of all materials. The structure with several fibre layers gives the cardboard excellent quality and optimum running properties in the printing, finishing and refinement processes. This is based on the general properties of wood fibres:
- The fibres interlock and combine to form a strong, homogeneous structure
- Thanks to their flexibility, shape and dimensions, fibres can form a uniform mesh
- During the manufacturing process, the properties of the fibres can be positively altered
The multi-layer structure allows the properties of the fibres in the individual layers to be optimised so that the cardboard can perform specific tasks. This is made possible by the different composition of the individual layers, which is achieved, among other things, by varying the proportion of long and short fibres in each layer.
Folding boxboard is divided into the following classes, which differ primarily in terms of the fibres used and the surface treatment:
Folding boxes in any size
At packaging warehouse, we manufacture your folding boxes from the following types of cardboard:
- Chrome board
- Recycled cardboard
- Cellulose cardboard
- Natural cardboard (light brown/black)
- Grass cardboard
They are suitable for a wide range of products, including folding boxes with tuck-in flaps, folding box with hinged lid, counter displays and cardboard slipcases. You don't have to settle for standard formats when it comes to the dimensions of your folding box – with us, you can freely determine the size of your folding box and have it cut to fit your products exactly. The values for length, width and height always refer to the internal dimensions of the boxes and range from 15 x 8 x 25 mm to 300 x 198 x 420 mm. Depending on the size you choose, different material thicknesses are available. This ensures the right stability for the size and weight of your product.
There are two ways to select the shape of your folding box:
- You select your cardboard product directly on our website
- You send us the ECMA code of your desired packaging
The ECMA codes provide an overview of various shapes for die-cut packaging and foldable cardboard boxes. In addition to packaging manufacturers in Europe, the codes are now also used by many companies in North America and on other continents.
As we do not have a minimum order quantity, you can order folding boxes from us starting from just one piece. With express production, we can manufacture your folding boxes within three working days – meaning your order will be with you in five working days at the latest!
All our folding boxes can be printed over the entire surface. This means you can have the outside and inside of your folding box printed – from single-colour logos to elaborate designs in CMYK or even Pantone special colours. Digital printing is selected as the default option in our configurator, allowing even small print runs to be printed cost-effectively. However, offset printing is also available for large order quantities. Our intelligent configurator calculates the best price without obligation and automatically selects the right printing process – for fast production in top quality.
The folding box and its functions
Despite its versatility, the folding carton is and remains a product packaging – it protects goods from external influences and is indispensable for efficient transport. In addition, American cardboard boxes have enormous marketing potential – their visual and haptic qualities are indispensable for brand image, customer loyalty and sales success. In the retail sector in particular, attractively designed folding boxes are often decisive in the purchase of a product. And with a high recycling rate of 80%, cardboard folding boxes are comparatively sustainable packaging – especially since cardboard fibres can be recycled multiple times.
Folding boxes thus offer a whole range of advantages, as they combine various tasks and areas:
- Presentation of the brand and product on the shelf or in the online shop
- Individual design as a distinguishing feature from competing products
- Signals the value of a product
- Product protection and quality assurance
- Appealing presentation area – even for smaller products
- Tamper-proofing / originality protection for e.g. food or expensive cosmetics
- Possibility of combining products within one package
- Contribution to the sustainability of a product
As an essential component of a product, folding boxes are largely responsible for brand perception and image.
Marketing with folding boxes
It is no secret that attractive packaging can be an incentive for consumers to buy, from a product marketing perspective – but a folding box has many other functions that are crucial for successful marketing. This is because folding boxes
- Attract attention
- Stand for innovation and quality
- Assisting with brand communication
- Enable a multisensory customer experience
- Signal authenticity and value, and
- Easy to use.
In order to exploit the full potential of folding cartons in marketing, the product and packaging must act as a single unit. Poorly made or even missing packaging can, in the worst case, give the impression that the customer is looking at an inferior product. A strong brand and successful, informative packaging design are therefore inextricably linked.
In order to exploit the full potential of folding cartons in marketing, the product and packaging must act as a single unit. Poorly made or even missing packaging can, in the worst case, give the impression that the customer is looking at an inferior product. A strong brand and successful, informative packaging design are therefore inextricably linked.
With their excellent printability and high functionality, folding boxes in particular are packaging with high advertising potential – as an effective communication medium that attracts the attention of the target group and has direct customer contact. Successful aesthetics and creative design ensure better perception and, in the best case, increase the willingness to pay a higher price for a product with attractive packaging.
Even after purchase, folding boxes often remain in use at home, thereby strengthening the relationship between the brand and the consumer. Sustainability also plays a role here: cardboard, as a material made from renewable raw materials with good recycling properties, is considered environmentally friendly by consumers of all ages.
One box – many possibilities
In addition to their classic role as product packaging, folding boxes can also perform other representative tasks in retail. These include, for example, counter displays that combine two functions: as collective packaging for smaller goods such as snacks, teas or cosmetics, the boxes are reliable packaging – at the same time, when opened, they form an advertising space that attracts customers' attention directly at the point of sale. You can also have your Counter display attractively designed by us – e.g. with full-surface printing and finishing – to make the best possible impression in stores.
At the same time, folding boxes offer excellent protection as secondary packaging, which can be further enhanced with matching cardboard inserts. The cardboard inserts give the packaging additional stability and, with their precisely fitting cut-outs, are ideal for the safe storage of sensitive goods such as ampoules, jars or even chocolates. At packaging warehouse, you can of course also have your inlay printed, which, especially in combination with a folding box with hinged lid or Telescope boxes, provides a large presentation area.
Folding boxes also ensure secure product protection as shipping packaging – from smaller and lighter items to books, folding boxes are suitable for shipping products. At packaging warehouse, you can order the specific dimensions for your product and shipping packaging – this allows you to determine the size of your folding box and adapt it precisely to your product. This also makes it possible to create packaging that not only provides excellent product protection but can also be posted through a letterbox.
But the folding boxes themselves are also ideal for shipping and storage – they are glued together after manufacture and packed flat, so they can be shipped and stored in a space- and resource-saving manner. They only reach their final shape when they are unfolded for filling.
Our types of folding boxes
At packaging warehouse, you can choose from many box shapes and types of cardboard to configure your box type. The different types are suitable for many product types and applications – so you should clarify all questions regarding weight, size, sensitivity, etc. in advance to find the optimal packaging for your product. For more information on choosing the right box types, materials and box bases for your product, see our magazine article ‘Which box for my product?’.
Folding box with tuck-in flap
The classic in our range impresses with its simple design and excellent value for money – it's no surprise that Folding boxes with tuck-in flaps are our top sellers. Available with offset and opposite flaps – mirrored or parallel. The side dust flaps prevent dust or foreign objects from entering the packaging and also act as a locking mechanism for the tuck-in flap.
Hinged box
The tuck-in flaps on the hinged lid make it particularly easy and secure to close. This makes the box ideal as simple outer packaging, fully printed product packaging or refined gift packaging for cosmetics, books and many other products. Not only are they well protected in the folding box with hinged lid, they also convey important information and ensure appropriate product presentation. The hinged box does not require any adhesive and gets its stability from the double side walls, which are simply turned over during assembly.
Folding boxes with security flap
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With their additional closure on the upper tuck-in flap, folding boxes with security tabs offer additional protection for the packaged products. The counter-lock is achieved by means of a tab (locking tongue) on the top of the folding box, which is inserted into a pre-punched slot in the insert tab when closing. This ensures that the box is closed particularly securely, but also makes it somewhat more difficult to open – which, from an unboxing perspective, can also enhance the experience and perceived value.
Counter display
On the one hand, this folding box protects the items it contains, and on the other hand, it gives them an eye-catching appearance. When closed, a counter display is a space-saving form of packaging; when opened, it attracts attention thanks to additional advertising space. Ideal for shop counters, checkout areas or sales shelves – thanks to the fold-up closure flap, which becomes the back wall of the display, your products will be an eye-catcher at the POS.
Inlay / Cardboard insert
Folding boxes are sturdy product packaging – but in certain cases, the packaged goods need additional protection. With an inlay / cardboard insert from packaging warehouse, the contents are securely fixed in place and cannot slip during transport. In addition to providing extra security, inlays can also enhance the appearance of packaging: precisely fitting cardboard inserts are used to secure products in gift sets, which are optimally presented through a window cut-out in the folding carton.
Gable boxes
The Gable box owes its name to the pointed closure at the top, which provides additional stability to the resealable box. Its shape makes it particularly suitable for products that must not be crushed, but it is also a popular gift packaging for teas, spices, chocolate and other loose products such as jewellery, socks or T-shirts.
Folding boxes with Euro hole suspension
The standardised Euro hole in the upper tuck-in flap makes the folding box with Euro hole hanging the ideal packaging for the point of sale. With three base types (tuck-in flap, tuck-in base, automatic base), it is suitable for light to heavy products. Alternatively, packaging warehouse offers Euro slot hangers that are suitable for gift cards, for example.
Carry handle box
The carry handle box is a suitcase-style folding box with a handle that is assembled from the front and back of the box and secured by side tabs. The resealable packaging is mainly used for information material and brochures, e.g. at trade fairs. The sturdy packaging is stable and quick to assemble, which also makes it suitable for use directly at the POS.
Pillow box
The pillow box is an elegant packaging solution for compact products, from soap to jewellery. The pillow box impresses not only with its versatile design options, but also with its extravagant convex shape. This makes the box not only very stable, but also offers a high level of protection with minimal material usage and low weight.
In addition to the folding box variants mentioned above, you can also order folding boxes with separators, slipcases, Euro slot hanger and flat cardboard sleeves without fastener from packaging warehouse. Of course, you also have all the options for configuring your product with these types of packaging – the various types are printable and can be produced with all available cardboard types and options.
The base types of our folding boxes
While the top of a folding box is usually closed with an insert flap, there are several options for the bottom of a folding box. The main factors to consider here are the load-bearing capacity of the design, the packaging, reliability, time savings, costs and handling. At packaging warehouse, you are sure to find the right option for your product. You can order the following types of bottoms from us:
- Folding boxes with tuck-in flaps
- Folding box with snap lock base
- Folding box with crash lock base
Insert tab
Folding boxes with tuck-in flaps are rectangular or square boxes that are glued on the side and where the lid and base are closed with a tuck-in flap – a protruding part of the box. This makes it easy to close the boxes without the need for aids such as glue or adhesive tape. Even though the tuck-in flap securely closes the box, the folding box may open again during transport or storage. There are three different types of tuck-in flaps:
- With the locking closure, the cardboard is cut into on both sides at the edge between the lid and the flap, so that the flap is locked by the dust flaps when closed.
- The locking tab is an additional small tab located opposite the actual insertion tab. It is inserted into a slot between the lid and the insertion tab, thereby sealing the box very securely.
- The insert tab with side flaps consists of two tabs on the box that are inserted into the side slots of the packaging when closing, thus securing the hinged lid.
Another advantage of boxes with tuck-in flaps is that the box closure is already integrated. This means that boxes with tuck-in flaps can be opened and closed again and again.
Plug-in base
The simple design and the option to reopen the box at any time to store the packaging flat are the two biggest advantages of the folding box with tuck-in base. No accessories are required to close the tuck-in base – unlike the tuck-in flap, the base consists of four differently shaped flaps that are simply tucked into each other to close the bottom of the folding box. The tuck-in base has a similar stability to the automatic base and is also cheaper due to the lack of adhesive points. Manual folding alone gives the automatic base a time advantage over a tuck-in base construction. From a weight of 500 grams, both the tuck-in base and the automatic base reach their limits – in this case, we recommend Cardboard Boxes.
Crash-lock base
The closure, also known as a flash bottom, allows the folding box to be set up in a single step. To do this, the side walls of the box only need to be pressed together slightly and the automatic bottom unfolds and closes the lower opening of the folding box. To achieve this, two bottom flaps are glued together and folded so that a closed and load-bearing bottom is created when the box is erected. The advantages are, on the one hand, the time saved by the quick assembly of the box, which also works with machine filling – on the other hand, the base is also suitable for heavy products and is therefore the most resilient of all three base types.
Assembly instructions for our folding box types
Each of our folding boxes has its own special features. With the right experience and a few clever tips, assembling the boxes is extremely easy. In the following videos, we show you how to effortlessly assemble folding boxes, folding box with hinged lid, counter displays and many other box variants.
Sample copy
Would you like to get a realistic overview of the numerous types of folding boxes and bases available? At packaging warehouse, you can order a sample box containing various types of folding boxes. The package includes a selection of printed folding boxes made from the different materials we offer. This allows you to get a precise impression of our portfolio – both visually and haptically. You will also receive a 5% voucher with every order.
Sectors
Thanks to the wide range of types, materials, formats and options available, folding boxes are ideal packaging for many industries – from the food industry and pharmaceutical sector to manufacturers of luxury goods. The range of applications is vast: from smaller cosmetic items, sweets, electronic components, promotional items and jewellery to larger products such as toys, textiles and household appliances.
Food
Food packaging belongs to the group of food contact materials – this means that folding boxes used to package food must not release any substances that could compromise food safety. This naturally also includes protecting the packaged food from contamination or damage. Folding boxes for food also protect against harmful environmental influences such as light, oxygen or moisture – they also prevent microorganisms, changes in aroma and vitamin loss, as well as foreign odours.
In addition to these basic requirements, food packaging also has a decisive influence on purchasing decisions. In the food industry, too, packaging acts as an ambassador for the brand and must convince consumers with its design and quality, as well as containing all relevant food labelling information.
Food is often additionally sealed in foil before being placed in the box – however, the folding boxes from packaging warehouse are also suitable for direct food contact. For greasy products, we offer a food-safe inner laminate – this protective plastic layer prevents the box from being damaged or greased and, conversely, prevents external influences from reaching the food.
Cosmetics
Folding boxes are primarily used in the cosmetics industry as secondary packaging for jars, tubes, bottles, nail polish, lotions, mascaras and many other cosmetic products. Similar to food packaging, all important information about the product must also be displayed on packaging for cosmetic items. This includes:
- Intended use of the product
- Inhaltsstoffe
- Best-before date
- Precautions for use
- Batch number
- Company and address
- Country of origin
The impact of cosmetic packaging or folding cartons on consumers is naturally very important, because in addition to safety, aesthetics and brand communication are key characteristics of successful cosmetic packaging. As a marketing tool, cosmetic packaging can directly influence consumers and is indispensable for communicating with the target group. An impressive corporate design not only ensures customer loyalty and differentiation from the competition, but can also influence the success or failure of a product. However, product protection and stability as well as safe transport are also relevant for cosmetic products and an important task for folding boxes.
Pharmaceutical
Folding cartons are used in the pharmaceutical, healthcare and CBD industries as secondary packaging for solid, liquid and semi-liquid medicines. They serve as packaging for ampoules, bottles, blister packs, jars and medical technology products and also contain product information (package inserts).
During production, manufacturers must comply with applicable GMP and FDA regulations and also take current quality and safety standards into account. Folding boxes for the pharmaceutical industry must meet high requirements in terms of whiteness, bending stiffness, thickness, creatability and codability in order to protect medical products from external influences such as moisture, dust particles and scratches.
The materials typically used are fresh fibre cardboard (GC) and cardboard made from secondary fibres (GD or GT) with grammages between 220 and 380 g/m², which reliably fulfil the tasks required. Production requirements for folding boxes for the pharmaceutical industry are also increasing:
- Continuous optimisation of the transport function
- Constantly increasing packaging output with smaller order sizes
- Embossing of Braille
- Compliance with presentation rules (‘blue box’ for centralised authorisations by the EMA)
- Special colours for hazard warnings
- Additional labelling and serialisation using adhesive labels, barcodes or 2D matrix codes
- Printing with variable data within the packaging machine
- Serialisation with adhesive labels, 2D matrix codes, barcodes
Marketing & Gifts
Whether as a marketing tool at trade fairs, a giveaway at major events, a promotional item in supermarkets or a gift box for holidays and birthdays, custom cardboard boxes are packaging that sticks in people's minds and, in the best case scenario, makes your brand or company even better known. A folding box with hinged lid in particular is perfect for marketing or gift packaging due to its versatility.
The possibilities are endless: carrying handle box with tuck-in flap for trade fair visitors, promotional boxes for advertising items, limited edition folding boxes with tuck-in flap for special promotions – if the packaging appeals to the customer's senses, the brand and products will also remain in their memory. Finishes such as a lacquered or laminated surface, 3D embossing or hot foil stamping in gold, silver and bronze can be helpful in attracting customers.
An attractive appearance is also important for folding boxes used as gift boxes – for birthday presents, boxes for wedding favours or gift packaging for Christmas, Easter or Valentine's Day.
The right gift packaging contributes to the overall visual experience and is ideal for cosmetics, perfumes, vouchers, wine bottles, jewellery or books. But folding boxes in their various types can also be used as tastefully designed photo boxes.
Automotive and electronics
Folding boxes are indispensable in the automotive accessories sector when it comes to packaging small to medium-sized spare parts. The boxes, designed in line with corporate identity guidelines, are used for many product groups, which can be divided into different sub-areas depending on their intended use. These include, among others:
- Food
- Windscreen wiper
- Tools
- Cleaning and care products
- Spark plugs
- Screws, nuts, washers
Here, too, you can configure the various cardboard materials, grammages and types of our folding boxes precisely to your requirements. For automotive parts, but also in the electronics sector, secure packaging and a good fit for the products in the box are essential. For this purpose, we recommend our custom-made inlays, which prevent slipping inside the packaging and can also be printed in the design of the folding box. Smaller electronic products are ideal for presentation in shops hanging in a folding box with Euro holes – other items benefit from a folding box with a viewing window. Here, too, you have complete freedom in terms of the design and selection of your folding box packaging.
Einzelhandel und Verkauf
The retail sector stocks products from a wide variety of industries – and therefore also a large number of folding carton packaging solutions. DIY stores, chemists and supermarkets stock many different types of boxes, all designed to appeal to customers. This is because products have direct contact with customers at the point of sale and are intended to encourage them to buy and repurchase. The diverse ways in which folding boxes can be used in retail are illustrated by this overview of the product range of a chemist's:
- Make-Up: Lippenpflege, Maniküre Tools, Kosmetiktücher, Haarfarbe, Mascara, Wattestäbchen
- Pflege & Parfüm: Serum, Cremes, Rasierklingen, Pads, Gesichtswasser, Parfüms, Badezusätze
- Gesundheit: Pflaster, Bonbons, Tabletten, Nahrungsergänzungsmittel, Zahnpasta, Zahnbürsten
- Ernährung: Tee, Kaugummi, Schokolade, Thunfisch, Kekse
- Haushalt: Müll- & Gefrierbeutel, Taschentücher, Spül- und Waschmaschinentabs, Reinigungstücher
Im Handel werden Faltschachteln oft als Sekundärverpackungen eingesetzt, die durch ihre optischen und haptischen Qualitäten sowie ihre Informationen Kunden zum Kauf animieren sollen. Aber auch die gute Lager- und Transportfähigkeit sowie die Stapelbarkeit der Faltschachteln macht sie ideal für den Einzelhandel. Durch die verschiedenen Formen ergibt sich auch eine große Flexibilität bei der Warenpräsentation im Laden – eine ansprechende Aufstellung verschiedener Beutelschachteln, eine dekorative Schale voller Kissenschachteln oder direkt an der Kasse hängende Faltschachteln mit Eurolochung machen die Waren attraktiver und fallen den Kunden direkt ins Auge.
Faltschachtelmaterialien
Faltschachteln können aus vielen verschiedenen Kartonsorten hergestellt werden. Dabei unterscheiden sich die einzelnen Kartons in Farbe, Dicke, Oberflächenbeschaffenheit und den verwendeten Faserarten. Um die Kommunikation zwischen den Karton- und Faltschachtelherstellern zu vereinfachen, gibt es für die verschiedenen Sorten Kurzbezeichnungen, in denen wichtige Merkmale codiert sind und die aus zwei Großbuchstaben und einer Ziffer bestehen. So steht der erste Buchstabe für die Oberfläche
- A: gussgestrichen
- G: gestrichen
- U: ungestrichen
und der zweite Buchstabe für den verwendeten Faserstoff:
- Z: gebleichte Primärfasern (Zellstoff)
- N: ungebleichte Primärfasern (Zellstoff)
- C: Primärfasern (Holzstoff)Type your text
- T: Sekundärfaser, Kartonrückseite weiss, gelb oder braun
- D: Sekundärfaser, Kartonrückseite grau.
Die Zahl nach der Buchstabenkombination bezeichnet entweder die Rückseitenfarbe (außer bei GD und UD)
- 1 weiß
- 2 hell (gelb)
- 4 braun
oder kennzeichnet das spezifische Volumen (nur bei GD und UD):
- 1 > 1,45 cm³/g
- 2 1,3 – 1,45 cm³/g
- 3 < 1,3 cm³/g.
Weiter Informationen zu den Kartonsorten und Abkürzungen findest du auch im ABC zu unseren Karton-Materialien. Bei packaging warehouse kannst du aus sieben Kartonsorten wählen:
Faltschachtel-Herstellung
Der Herstellungsprozess einer Faltschachtel besteht aus mehreren Produktionsschritten – die Kartonbögen werden zuerst bedruckt, danach gestanzt, veredelt und schließlich geklebt. Dazwischen gibt es jedoch eine Reihe an Optionen und Varianten, die entsprechenden Einfluss auf das fertige Produkt haben.
Druckprozess
Beim Druck der Faltschachtel kommen bei packaging warehouse zwei Druckverfahren zum Einsatz - der Digitaldruck und der Offsetdruck. Ausschlaggebend ist dabei nicht die Qualität, sondern die Wirtschaftlichkeit. Der Digitaldruck als Non Impact Verfahren (NIP) benötigt keine Druckplatten und eignet sich vor allem für kleine und mittlere Auflagen. Der Offsetdruck kann auf die Druckplatte nicht verzichten, liefert jedoch eine sehr gute Druckqualität in sehr kurzer Zeit, was ihn für hohe Auflagen zur wirtschaftlicheren Druckvariante macht.
Nach dem Bedrucken erfolgt die sogenannte Veredelung – unter diesem Namen werden verschiedene Verfahren zusammengefasst, mit denen die Oberfläche des Kartonbogens optisch attraktiver, aber auch widerstandsfähiger wird.
Lackierung
Lacke bilden auf der bedruckten Oberfläche einen glatten und dichten Film, der dekorative und funktionelle Eigenschaften besitzen kann.
- Schutzlack - Ein schützender Lackfilm, der die Oberfläche vor Verscheuern und Verschmutzen schützt.
- Glanz- und Mattlack - Auf Glanz- und Matteffekte spezialisierte Lackierungen.
- Effektlack/3D Lack - Durch zugemischte Pigmente (Bronze, Aluminium) entsteht ein spezieller Effektlack. Durch unterschiedliche Schichtdicken können auch Oberflächenreliefs bis hin zur Blindenschrift realisiert werden.
- Aussparungen/Spot-Lackierungen
Heißfolienprägung
Die Heißfolienprägung wird bei Faltschachtelkartons zur Erzeugung glatter und glänzender Flächenelemente aus Gold, Silber und anderer Metallicfarben eingesetzt. Der Effekt wird durch einen sehr dünnen Lackfilm erzeugt, der auf einer Seite metallisiert ist bzw. mit einer dünnen Farbschicht versehen wurde. Die Bezeichnung Heißfolienprägung erschließt sich aus der Verwendung einer dünnen PET-Folie auf die nacheinander folgenden Schichten aufgetragen werden:
- Trennschicht – trennt Folie und Lack / extrem dünn
- Schutzlack – Lackfilm / Schützt die Metallisierung
- Metallisierung – Metallic Effekt durch Bedampfung / alternativ Farbauftrag
- Haftschicht – Hotmelt / verbindet Lack und Metallisierung mit dem Karton
Die Folie wird in geringem Abstand über den Karton gespannt und dann mit einem beheizten Werkzeug mit Druck und Hitze geprägt. Durch die Wärme wird die Haftschichtaktiviert, wodurch sich der metallisierte Lackfilm auf der Kartonoberfläche haften bleibt – aber nur im beheizten Bereich. Somit bleibt nur das Prägemotiv auf dem Bogen sichtbar, wenn der Stempel zurückgeht und sich die Folie wieder strafft. Mit der Heißfolienprägung sind nicht nur glatte und glänzende Elemente möglich - auch Reliefprägungen und Hologramme lassen sich mit dieser Methode realisieren.
.gif "Heißfolienprägung auf einer Faltschachtel")
Stanzen & Rillen
Nach dem Drucken und Veredeln des Kartonbogens erfolgt das Stanzen – bei diesem Prozess werden die Kartonbögen im Stanzautomaten in die einzelnen Zuschnitte aufgetrennt. Auch das Rillen an den späteren Faltlinien und weitere Bearbeitungen wie das Prägen oder Ritzen erfolgen in diesem Schritt. Für die Stanzung des Bogens gibt es bei packaging warehouse zwei unterschiedliche Verfahren – die Laserstanze sowie die konventionelle Stanze:
Laserstanze
Die Stanzung des Werkstücks mittels Laser wird nochmals in zwei Fertigungsarten unterschieden. Bei der Laserstanze wird sowohl die Kontur als auch die Faltlinie mit dem Laser ausgeschnitten. Die konventionelle Laserstanze schneidet nur die Kontur der Faltschachtel mit dem Laser aus – die Rillung wird mit speziellen Matten erzeugt, die im 3D-Drucker mit dem Rillmuster bedruckt werden. Diese Matten werden dann beim Prozess mit in die Laserstanze gelegt.
Konventionelle Stanze
Beim konventionellen Stanzen wird ein Bandstahlschnitt-Werkzeug verwendet. Dabei handelt es sich um eine Holzplatte mit Stanzmessern, Rilllinien und Auswerfgummis, die sich in der Maschine auf und ab bewegt und so die Kontur aus dem Bogen stanzt. Diese Stanzart lohnt sich ab einer mittleren Auflage, wobei die Kosten der Stanzvorlage zwischen 150 und 1000 € liegen - je nach Größe, Nutzenanzahl und Komplexität z.B. durch eine Logo-Hochprägung.
Rillen
Wie der Name schon sagt, wird erst durch das Falten aus einem gestanzten Kartonbogen eine Faltschachtel. Unverzichtbar ist dabei das Rillen des Kartons an der Falzlinie – nur so lassen sich Risse in den oberen Lagen des Materials verhindern. Im Idealfall entstehen so klar definierte Falzlinien, die den Faltvorgang vereinfachen und damit die Grundlage für die Form und Funktionalität der Faltschachtel schaffen. Der Prozess ist ähnlich einer Prägung: Mithilfe einer dünnen Stahlleiste (dem Rillmesser) und einer präzisen Nut (der Rillmatritze) wird beim Stanzen eine dauerhafte Rille in den Karton gedrückt. Diese Falzlinie dient dann beim Falten als eine Art Scharnier – der Karton ist an diese Stelle geschwächt und lässt sich durch den geringen Biegewiderstand in die gewünschte Form falten. Je nach Kartonart müssen die Rillwerkzeuge angepasst werden, um optimale Ergebnisse erzielen zu können.
Kleben
Nach dem Stanzen werden die Faltschachteln in ihrer finalen Form aus dem Bogen gebrochen und in die Klebemaschine gelegt. In diesem Schritt werden die Zuschnitte am Kleberand verleimt – die Maschine übernimmt dabei das Aufbringen des Leims, das Umlegen der Schachtel an den Faltlinien und das Zusammenpressen an der Verbindungstelle, bis der Leim ausgehärtet ist. Je nach Faltschachtelgröße, Material und Oberflächenbeschichtung wird beim Kleben der Schachtel entweder Kaltleim oder Heißleim verwendet, wobei der Heißleim strapazierfähiger ist. Manchmal werden die Klebestellen auch in der Klebemaschine angefräst um die Oberfläche etwas aufzurauen und somit die Hafteigenschaften des Klebers zu verbessern.
Auch die Anzahl der Klebepunkte unterscheidet sich bei den verschiedenen Faltschachteltypen: Eine normale Faltschachtel mit Einstecklaschen z.B. hat einen Klebepunkt, eine Schachtel mit Automatikboden drei Klebepunkte. Bei packaging warehouse können wir bis zu 4 Klebepunkte anbringen.
Mit dem Kleben endet die Verfahrenskette von einem Kartonbogen hin zu einer funktionalen und optisch ansprechenden Faltschachtel. Als letzte Schritte folgen nun noch das Abpacken und der Versand der flachliegenden Faltschachteln, bis sie beim Kunden befüllt werden und damit eine ihrer vielfältigen Aufgaben übernehmen können.
Nachhaltigkeit
Als Verpackung aus nachwachsenden Rohstoffen und der guten Recyclingfähigkeit werden Faltschachteln auch von Verbrauchern aller Altersstufen als nachhaltige Verpackung gesehen und beim Kauf auch bevorzugt. Die sichtbaren Vorteile sind dabei die Fertigung des Kartons aus nachwachsenden Rohstoffen - Holzfasern und Zellulose bzw. Aufbereitetes Altpapier – und die gute Recycelbarkeit der Papierfasern, die 5-7 mal wiederverwendet werden können.
Für die Produktion von Frischfasern werden in Europa – ähnlich zur Herstellung von Wellpappe – vorrangig Bruch- und Durchforstungsholz, Sägewerksnebenprodukte und Plantagenholz eingesetzt. Durch die nachhaltige Bedwirtschaftung der europäischen Wälder, sind deren Flächen seit Beginn der neunziger Jahre kontinuierlich gewachsen.
Außerdem gewinnt die europäische Zellstoff-, Papier- und Kartonindustrie über die Hälfte ihrer Energie aus der Biomasse von biologischem, meist pflanzlichem Material – so erzeugen die Holznebenprodukte erneuerbare Energie für die Produktion. Um den hohen Wasserverbrauch zu kompensieren, werden 95 % des Wassers gereinigt und wiederverwendet. Den Strom für die Produktion (fast 97 %) liefern Kraft-Wärme-Kopplungsanlagen (KWK), in die schon über 90 % der europäischen Fabriken investiert haben. Damit ist die Herstellung nicht nur ressourcenschonend, sondern verleiht unseren Kartons auch einen positiven CO²-Fußabdruck.
Beim Thema Nachhaltigkeit und Faltschachteln stellt sich oft die Frage nach der Wiederverwertbarkeit von beschichteten Papierverpackungen. Im Verhältnis zu reinen faserbasierten Verpackungen ist die Menge an Verbundstoffen im Altpapier sehr gering. Des weiteren können die Papierverbunde in Standard-Recyclinganlagen recycelt und die Fasern auch wiederverwertet werden. Wichtig ist dabei, dass die Faltschachteln auch dem Verwertungskreislauf zugeführt werden, wobei eine einheitliche Kennzeichnung der Verpackungen hinsichtlich der richtigen Entsorgung für die Verbraucher hilfreich wäre. Auch im Rahmen der Aufbereitung und Sortierung ist noch Raum für Innovationen, um die bestmögliche und sortenreine Verwertung von Verbundverpackungen zu ermöglichen.
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