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At Royal Paper Box, our expertise in structural design and prototyping is a vital part of our service. With years of experience, we specialize in creating custom folding cartons for the biotech, medical devices, pharmaceutical, and personal care industries. Our team of experts collaborate closely with clients to fully comprehend their specific packaging requirements. We provide customized guidance and creative solutions that perfectly align with your brand’s vision and objectives.

Employee Folding a Prototype

Folding Carton Types

In the world of packaging, the variety of folding paper boxes available can be overwhelming. Each type serves a unique purpose and offers specific benefits, making them suitable for various products and industries.

Reverse Tuck End
Reverse Tuck End Schematic
Vertical stadning Reverse Tuck End

Reverse Tuck End

The Reverse Tuck End (RTE) box, much like the Straight Tuck End box, features flaps that tuck in opposite directions: one flap tucks from front to back, while the other tucks from back to front. This configuration enhances nesting efficiency in die-cutting and print layouts, making it ideal for automatic filling lines.

  • Ideal for lightweight products
  • Quick loading
  • Easy set up
  • Compact storage (packed flat in cases)
  • More affordable than STE due to better nesting capabilities

Ideal uses: This compact carton is suitable for a wide range of products, including pharmaceuticals, cosmetics, and small electronics.

Straight Tuck End
Straight Tuck End Schematic
Straight Tuck End standing up vertically

Straight Tuck End

Straight Tuck End (STE) boxes are a popular choice for retail packaging. With both the top and bottom flaps tucking in the same direction, they offer a sleek and professional appearance. These boxes are simple to assemble, and their design keeps the front panel clear, making them perfect for displaying branding and product details.

  • Ideal for lightweight products
  • Quick loading
  • Easy set up
  • Compact storage (packed flat in cases)

Ideal uses: Perfect for lightweight products like cosmetics, electronics, and food items.

Tuck Top Snap Lock Bottom schematic
Tuck Top Snap Lock Bottom standing vertically

Tuck Top Snap Lock Bottom

The Tuck Top Snap Lock Bottom (TTSLB) box, also referred to as a 1-2-3 bottom box, has a bottom that secures with interlocking flaps, making it ideal for heavier items. While this design is more economical than the auto bottom, it does require added assembly time.

  • Ideal for heavier products
  • Quick loading
  • Compact storing (packed flat in cases)

Ideal uses: Great for heavier items, making it a popular choice for products like candles, glassware, and small appliances.

Tuck Top Auto Bottom
Tuck Top Auto Bottom Schematic
Vertical standing Tuck Top Auto Bottom

Tuck-Top Auto Bottom

The Tuck Top Auto Bottom (TTAB) box offers efficient and easy assembly. The top flap tucks neatly into the front, while the bottom automatically folds into place. The glued bottom flaps create a sturdy base without requiring extra adhesives. This box can be made with or without slit locks on the top tucks for secure closure.


  • Ideal for heavier products
  • Quick loading
  • Easy set up
  • Compact storage (packed flat in cases)

Ideal uses: This strong structure is perfect for retail packaging, subscription boxes, and e-commerce orders.

Seal End
Seal End Schematic
Seal End standing vertically

Seal End

Seal End (SE) boxes are renowned for their secure closure. Featuring overlapping flaps on both ends, these boxes are sealed with adhesive during the filling process, offering a tamper-evident packaging solution. This design ensures that contents stay protected during transit and storage. Additionally, cartons can be equipped with double-sided tape for hand-filling applications.

  • Tamper Evident 
  • Quick loading
  • Easy set up
  • Compact storing (packed flat in cases)

Ideal uses: These boxes are often used in industries where product safety and integrity are crucial, such as food, cosmetics, and pharmaceuticals.

Sleeve
Sleeve Schematic
Sleeve box standing vertically

Sleeve

The Sleeve is a versatile packaging choice that wraps around products or boxes, providing an added layer of protection and branding space. These sleeves can be pre-glued for easy assembly and can be customized with high-quality printing to enhance the product’s visual appeal.

  • Added protection.
  • Alternate product branding
  • Easy set up
  • Compact storage (packed flat in cases)

Ideal uses: Packaging for books, cosmetics, and other retail items and great for repurposing current packaging for promotional use.

Glued Double Side Wall
Glued Double side wall Schematic
Glued Double Side Wall with lid

Glued Double Side Wall

The Glued Double Side Wall (GDSW) carton offers protection due to the double layer of paperboard on the wall sides, enhancing durability and strength. These boxes can be used as an inner tray and grouped with an outer sleeve, or even have a second glued double side wall that acts as a lid for even more protection. The double side walls can be glued for added stability. Additionally, the high-quality printing surface allows for attractive branding and product information display.

  • Added protection and stability.
  • Attractive and upscale style.
  • Quick loading
  • Compact storage (packed flat in cases)

Ideal uses: Perfect for heavier or fragile items, such as electronics, gourmet foods, and luxury items.

Royal Paper Box Box
Box Schematic
Slightly ajar Royal Paper Box Box

Cherry Lock Tray (Mailers)

The Cherry Lock Tray (CLT), also known as a mailer, is a specially designed die-cut container ideal for smaller items. Its top folds over and locks securely, removing the need for sealing tape. This sturdy and sophisticated carton design has a robust locking mechanism that guarantees the safety of the contents during transit, ensuring a secure and reliable packaging solution. Double sided tape can be added for added security.

  • Added protection and stability
  • Attractive and upscale style
  • Quick loading
  • Compact storage (packed flat in cases)

Ideal uses: Great as a gift box or to be used as a mailer for various products such as books, clothing, and accessories.

Beers Tray Schematic
Beers Tray with lid

Beers Tray

The Beers Tray (BT), also known as a Four Corner Beers Tray, features a sturdy frame that provides excellent support and durability. This versatile tray works well as a tray or a gift box when ordered as a two-piece set to be used as a tray and lid. Its durable construction ensures that the contents stay secure and protected during handling.

  • Quick loading
  • Versatile and convenient
  • Quick loading
  • Compact storage (packed flat in cases)

Ideal uses: These trays work great as a gift box, 2-piece display type box organization and storage.

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Frequently Asked Questions

If you have a question not addressed here, please click the link below to view more.

View All FAQ

How long does it take to make a sample?

Can you make a design sample from my artwork?

I don't see the folding carton style I envisioned. Do you have other designs we can use?

What type of paperboard stock do you use for structural design samples?

Do you need my product to create the initial prototype?

Do you charge for CAD samples?

Royal paper Box

Contact Us

Need assistance with your project? Send us a note and our sales team will reach out for more information. We have a structural design and rapid prototyping department that help you.

For immediate attention call us!
Telephone (323) 728-7041

Business Hours
Monday thru Friday
8:00 AM to 5:00 PM

Royal Paper Box Co Building

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