11/07/2025
Corrugated Boxes are one of the most revolutionary inventions in the packaging and logistics industry. Their greatest strength lies in the ability to balance two seemingly opposing qualities: optimal product protection while remaining lightweight and easy to handle—thanks to intelligent structural design and durable, flexible corrugated paperboard.
With advances in printing technology and modern finishing techniques, the traditional brown corrugated box has undergone a remarkable transformation—evolving into visually appealing, high-end designs ranging from minimalist, eco-friendly styles to luxurious, intricate packaging for festive seasons like Mid-Autumn gift boxes or Lunar New Year hampers.
In this feature, Newlifepack introduces 12 of the most common corrugated box styles, accompanied by standardized U.S. industry terminology. Each structure is thoroughly analyzed in terms of technical construction, real-world applications, and key design considerations. This guide serves as a practical reference for businesses seeking optimal packaging solutions that not only reduce costs but also elevate brand image with impact and distinction.
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Hộp Nắp Đối Khẩu / Hộp A1
The Regular Slotted Box (RSC)—commonly referred to in Vietnam as Hộp Nắp Đối Khẩu or Hộp A1—is the most widely used and industry-standard corrugated box style. It is formed from a single sheet of corrugated board, with pre-scored lines that allow the box to be folded into a rectangular shape.
The key structural feature of the RSC lies in its flaps: all four flaps have equal width; the two longer flaps (outer flaps) meet in the center when closed, while the two shorter flaps (inner flaps) do not meet.
This box type is suitable for a broad range of industries, including FMCG, packaged food, electronics, industrial goods, and export shipments. It offers a cost-effective packaging solution with easy customization in size and print. Boxes can be flexo-printed for transportation use or enhanced with 4-color offset printing and surface finishes for retail packaging—enhancing both visual appeal and brand identity.
RSC boxes are typically made from single-wall or double-wall corrugated board, with flute types such as B, C, E, or combinations like BC or EB, depending on load requirements. The structure includes four continuous panels joined with a manufacturing joint using glue, staples, or industrial tape. Boxes are shipped flat-packed to minimize logistics and storage costs. Dimensions are measured internally in the following order: length × width × height.
To ensure optimal performance, it’s critical to select the appropriate flute type based on the product’s weight and fragility. The score lines must be accurately placed to avoid panel misalignment, bulging, or gaps when folded. For offset-printed boxes, a protective lamination or UV coating is recommended to preserve graphic quality. Additionally, the outer flaps should be precisely sized to meet cleanly at the center without overlapping or leaving gaps.
Hộp Cài Nắp Đáy Cùng Chiều
The Straight Tuck End Box (STE) is a precisely die-cut corrugated box style where both the top and bottom flaps tuck in the same direction—typically toward the back panel. This configuration keeps the front panel of the box smooth and uninterrupted, free from cut lines or fold creases, making it ideal for designs that require clean presentation and strong brand visibility.
STE boxes are commonly used for lightweight, high-value products such as cosmetics, pharmaceuticals, dietary supplements, small electronic devices, fashion accessories, and premium handcrafted items. Thanks to their compatibility with high-quality offset printing and a wide range of surface finishes, STE boxes are a preferred choice for retail and commercial packaging. They are also flat-packed for storage and shipping, helping reduce logistics and warehousing costs.
STE boxes are typically made from lightweight corrugated board such as E-flute or F-flute, with a paper weight ranging from 250 to 400 gsm. The structure features a single-piece body, top and bottom tuck flaps on the same side, and a side glue flap. The manufacturing process includes offset printing, die-cutting, folding, edge gluing, and flat-packed delivery for easy assembly.
Because STE boxes do not have a locking mechanism, they are not recommended for heavy or fragile products that require enhanced protection during shipping. To increase security, tamper-evident seals or adhesive tape can be added. For more robust packaging needs, consider transitioning to styles with locking bottoms, such as Snap Lock Bottom or Auto Lock Bottom boxes.
To maximize branding effectiveness, the uninterrupted front panel should be used as the primary design canvas—ideal for showcasing logos, artwork, or promotional messages with visual clarity and impact.
Hộp Cài Nắp Đáy Ngược Chiều
The Reverse Tuck End Box (RTE) is a corrugated box style die-cut from a single sheet of carton—typically E- or F-flute—with a paper weight of approximately 250–350 gsm. Its key structural feature lies in the opposing direction of the tuck flaps: one flap folds toward the front panel, while the other tucks toward the back. This reverse configuration allows for efficient nesting during layout, reducing material waste while maintaining ease of use and reliable product protection.
RTE boxes are ideal for lightweight to medium-weight items that require fast assembly and cost-effective packaging, such as cosmetics, pharmaceuticals, nutraceuticals, candles, small accessories, or consumer electronics. Thanks to their quick setup and strong display appeal, RTE boxes are widely used in retail, e-commerce, and for brands seeking a practical yet refined packaging solution.
RTE boxes are commonly made from lightweight corrugated board (E or F flute), depending on structural needs. The construction includes a single-piece body with two opposing tuck flaps (reverse tuck closure) and one side glue flap. The production process includes offset printing, die-cutting, folding, gluing, and flat-packing for efficient storage and shipping. To assemble, simply pop the box open and tuck in both ends—suitable for both manual and automated packing lines.
While the reverse tuck mechanism offers better resistance to accidental opening than straight tuck end (STE) boxes, the overall protection still depends on material quality, friction-fit strength, and precision of the tuck slit design. For heavier items or when additional tamper resistance is needed, consider adding slit locks, tamper-evident seals, or switching to auto-lock bottom boxes.
One limitation of the RTE style is the asymmetry of the end flaps, which can disrupt the visual continuity of the box. This makes it slightly less ideal for premium packaging where a seamless front and back panel is desired. Accurate flap and slit design is essential to maintain structural integrity and aesthetic quality.
| Criteria | STE – Straight Tuck End | RTE – Reverse Tuck End |
|---|---|---|
| Aesthetic Appeal | High – seamless front panel ideal for premium display | Moderate – visible top/bottom flaps may interrupt design flow |
| Production Efficiency | Less efficient – flap direction requires precise folding | Optimized for mass production and quick packing |
| Material Optimization | Slightly more material usage | More efficient layout – saves paper and costs |
| Best For | Cosmetics, electronics, gourmet food, premium gifts | Pharmaceuticals, FMCG, e-commerce products |
| Professional Appeal | Enhances brand image and premium perception | Focuses on function and packing speed |
Summary – Choosing Between STE and RTE
Need a seamless, premium-facing display—even if it costs slightly more in materials?
→ Go with the Straight Tuck End (STE) box.
Looking to cut material costs and speed up packing—while accepting a visible front tuck flap?
→ Choose the Reverse Tuck End (RTE) box.
Hộp Đáy Khóa
The Snap Lock Bottom Box (SLB)—also known as the 1-2-3 Bottom Box—is a corrugated packaging style featuring a bottom closure formed by interlocking four flaps in a specific sequence. When folded correctly—hook-shaped main flap first, followed by two side flaps, and lastly a small locking flap that “snaps” into place—the structure creates a secure closure through friction alone, eliminating the need for glue or tape. This design enhances load-bearing strength while maintaining a lightweight and collapsible form.
Thanks to its higher strength compared to regular tuck-end boxes, SLB is well-suited for packaging medium-weight items such as large-volume cosmetics, small electronics, packaged food, glass bottles, personal care products, and accessories. It’s a practical solution for businesses seeking packaging flexibility, cost efficiency, and easy shipping. Moreover, SLB boxes can be flat-packed for storage, making them ideal for small- to medium-scale production runs.
SLB boxes are die-cut from a single sheet of corrugated board—typically E- or F-flute—with a basis weight between 250–350 gsm. The structure includes a continuous box body with tuck-top closure and a four-panel snap-lock bottom, secured via a side glue flap. The production process includes offset printing, die-cutting, folding, gluing, and delivery in flat-packed form. To assemble, simply pop open the box and fold the bottom flaps in the correct “1-2-3” order—no extra adhesives required, saving time and labor during packing.
To ensure secure bottom locking, it’s essential to follow the precise flap-folding sequence during assembly. Incorrect folding can result in a loose base that may collapse during transport. For heavier products, it’s advisable to conduct weight testing before mass production, and consider increasing board thickness or switching to a sturdier structure like an Auto Lock Bottom Box (ALB) or using B- or C-flute for greater support. Additionally, flap dimensions and die-line precision are critical to ensure the interlocking mechanism fits snugly and maintains shape under load.
Hộp Đáy Tự Động
The Auto Lock Bottom Box (ALB), also called the Crash Lock Bottom Box (CLB), is a corrugated packaging style featuring a pre-glued, interlocking bottom structure. When the box is popped open, the bottom panels automatically fold and lock into place via a combination of adhesive bonds and friction, creating a secure base without any need for additional taping or gluing. With a simple push, the bottom locks instantly—saving time and increasing efficiency in both manual and automated packing processes.
ALB boxes are ideal for medium to heavy-weight products such as pharmaceuticals, cosmetics, canned food, tech accessories, premium retail goods, and industrial supplies. Their fast assembly, load stability, and labor-saving benefits make them especially well-suited for high-throughput packing lines, fulfillment centers, and logistics hubs requiring speed and consistency.
These boxes are typically made from E-flute, B-flute, or EB double-wall corrugated board with a basis weight of 300–400 gsm. The bottom structure is designed using a crash-lock mechanism that locks automatically upon opening. Production includes offset printing, die-cutting, gluing the bottom flaps at the factory, and delivering the boxes in a flat-packed format. To use, simply unfold the box and the pre-glued base will automatically form—no extra adhesive required.
The locking performance depends on the accuracy of the bottom flap design and the quality of the adhesive application. Inconsistent or misplaced glue may cause the base to fail during shipping. For heavier contents, it’s important to choose the appropriate flute type—B-flute or EB for added rigidity—and consider increasing board thickness to enhance strength. To boost visual appeal and brand impact, ALB boxes can also feature value-added finishes such as lamination, spot UV, hot stamping, or metallized film lamination.
| Criteria | Snap Lock Bottom (SLB) | Auto Lock Bottom (ALB / CLB) |
|---|---|---|
| Bottom Structure | Four interlocking flaps secured by friction | Pre-glued bottom flaps that lock automatically when popped open |
| Assembly Speed | Moderate – requires manual folding in the correct sequence | Very fast – bottom locks instantly upon assembly |
| Weight-Bearing Capacity | Suitable for medium-weight products | Excellent – ideal for heavier items and bottles |
| Glue Requirement | Not required | Requires pre-applied glue at the factory |
| Production Cost | Lower – simpler bottom design | Higher – more complex structure with extra gluing step |
| Labor Efficiency | Requires manual folding for each unit | Significantly reduces manual labor |
| Common Applications | Cosmetics, light household goods, hand-packed food items | Premium cosmetics, pharmaceuticals, e-commerce, bottled products |
| Semi-Automated Line Compatibility | Compatible | Highly compatible |
Hộp Cuộn Nắp Cài Trước
The Roll End Tuck Front (RETF), also known as a Mailer Box or Aircraft Box, is a type of corrugated packaging known for its self-locking structure, achieved through dual roll-end side panels and a tuck-in front flap. The front closure features two locking tabs that insert into pre-cut slots inside the front wall of the box, ensuring a snug, secure fit that resists accidental opening. This box style is fully assembled by hand without glue or tape, offering excellent structural integrity and a firm, high-quality feel.
RETF boxes are ideal for products requiring both strong protection and high visual appeal—such as premium gifts, packaged food, cosmetics, fashion accessories, books, and e-commerce merchandise. They are especially popular in experiential marketing campaigns, upscale unboxing experiences, and direct-to-consumer (D2C) retail, where the unboxing process itself enhances brand value.
This style is typically made from E-flute or B-flute corrugated board with a basis weight of 300–400 gsm. The structure includes a main body panel, two roll-end side walls that fold inward to form a sturdy box shape, and a front flap with dual tuck tabs. Production steps include offset printing, die-cutting, and delivery in a flat-packed format. End users simply fold the side panels inward and tuck the front flap to assemble—no adhesive required.
Although RETF boxes offer a premium opening experience and durable build, manual assembly takes more time than styles like auto-lock bottom boxes or standard tuck-end boxes. Inaccurate folding can lead to misaligned flaps or compromised closure strength. For optimal performance, tuck slots must be precisely designed, and board rigidity must match the product’s weight. For large-volume orders, partial automation in the packing process is recommended to improve efficiency and reduce labor costs.
Hộp Nắp Liền
The Hinged Lid Box is a corrugated box style made from a single sheet of board, with the lid connected to the base by a back spine fold, also known as a hinged score line. Its one-piece design offers a clean, streamlined look, making it ideal for products that require frequent opening and closing, while also enhancing user convenience and aesthetic appeal. This structure is widely used due to its ease of production and reusability.
Hinged lid boxes are commonly used in e-commerce packaging, electronics, fashion, cosmetics, gifts, and light industrial packaging. The integrated lid allows for premium unboxing experiences and efficient shelf display, making it a strong option for retail-focused or D2C brands seeking elevated packaging presentation.
Hinged lid boxes are typically made from E-flute, B-flute, or EB double-wall corrugated board, selected based on the product’s weight. E-flute can support up to ~7 kg, while B or EB flutes can hold up to 14 kg or more. The structure includes the main body, a fold-over lid, and optional locking flaps or side tabs for added strength. Manufacturing involves offset printing, die-cutting, folding, gluing side seams, and delivery in either flat-packed (knock-down) or pre-assembled formats.
To ensure smooth lid operation, the hinge fold line must be precisely scored, and surface lamination (film coating) is recommended to prevent cracking along the fold. Lid dimensions and locking features must be carefully calculated to avoid unintended popping open during use. For heavier or shift-prone contents, consider adding reinforced fluting and custom inserts or inner trays to enhance stability and prevent product movement during transit.
Hộp Nắp Rời / Hộp Âm Dương
The Lift-off Lid Box, also known as a Base and Lid Box, is a premium corrugated packaging style consisting of two separate components: a bottom tray (base) and a removable top cover (lid). The lid fits over the base from the top and can be lifted off completely. While structurally simple, this rigid-style corrugated box delivers a refined, solid look and elevates the unboxing experience—making it a favorite for high-end packaging lines.
Lift-off lid boxes are ideal for presenting luxury items, gift sets, Mid-Autumn mooncakes, cosmetics, watches, fashion accessories, or custom branded products. The iconic design has remained timeless across modern packaging trends and is especially well-suited for premium gifting, retail displays, and mid-to-high-end e-commerce where presentation matters.
These boxes are typically produced in either flat-packed or pre-assembled formats, depending on storage and shipping needs. Materials include E-flute, B-flute, or EB double-wall corrugated board, laminated with coated paperboard such as couche, ivory, or duplex—usually in weights ranging from 600 to 2000 gsm. The outer surface is printed via offset printing and may be laminated to protect the design and prevent cracking at fold lines. Premium finishing techniques such as foil stamping, embossing, or spot UV can be added to enhance brand presence.
When designing lift-off lid boxes, precise sizing between the base and lid is essential for a snug yet smooth open/close mechanism. Loose-fitting lids can reduce perceived quality, while overly tight lids can hinder usability. For heavier items or those requiring added structural strength, switching to chipboard rigid boxes is recommended. Die-cutting and box assembly must be carefully executed to maintain clean lines and upright shape. If using internal inserts or trays, ensure their height does not interfere with lid closure, which could compromise both appearance and functionality.
Hộp Móc Treo
The Hanging Box is a corrugated box design that integrates a built-in hanging tab at the top, allowing products to be directly displayed on peg hooks at supermarkets, convenience stores, or point-of-sale (POS) areas. The hanger tab is pre-die-cut into common formats such as Euro hole (a keyhole with a round top and slotted bottom), Delta hole (a rounded triangular cut), Circle hole, or other custom shapes to match various retail display systems.
Hanging boxes are widely used for small-sized, high-value products that benefit from eye-level display, including FMCG items, cosmetics, toys, small electronics, mobile accessories, stationery, and household tools. This packaging style maximizes vertical space and shelf visibility, while enhancing brand recognition at the critical point of sale—making it a key asset in retail marketing strategies.
Hanging boxes are typically made from E-flute or B-flute corrugated board, with paper weights ranging from 280–400 gsm. The main body of the box can be constructed in several standard formats such as Straight Tuck End (STE), Reverse Tuck End (RTE), Snap Lock Bottom (SLB), or Auto Lock Bottom (ALB)—depending on the product’s size, shape, and weight. The hanging tab is integrated into the die-cut design, with pre-punched holes for hanging. Boxes are delivered flat-packed for efficient storage and shipping.
When designing a hanging box, it’s important to assess the load-bearing capacity of the hanger hole. For products weighing between 250–500 grams, consider using thicker corrugated board (e.g., B-flute) or reinforcing the hanger area with laminated board. The standard Euro hole width ranges from 32–38 mm, and corners should be rounded or edge-treated to prevent tearing during prolonged hanging. For heavier items or those containing liquids, internal reinforcements such as support trays or bottom pads may be required to improve structural stability while on display.
Hộp Quai Xách / Hộp Mái Nhà
The Handle Box, also known as a Gable Box, is a type of corrugated packaging with an integrated handle built into the top closure. The handle is formed from the same die-cut sheet as the box itself, using precise scoring and folding techniques. When the top flaps are folded inward, the two sides interlock to create a sturdy and convenient carrying handle. This structure strikes a balance between functionality and visual appeal, making it ideal for both practical use and retail display.
Gable boxes are widely used in food and beverage take-out services, confectionery, tea and coffee packaging, cosmetics, gift boxes, event giveaways, and conference kits. The integrated handle enhances portability and user experience, while also serving as a visual focal point that elevates brand image in marketing, retail merchandising, and short-distance logistics.
Handle boxes are typically made from E-flute or B-flute corrugated board, with paper weights ranging from 300–400 gsm. The box is die-cut from a single sheet, including the main body, bottom closure, gable flaps, and integrated handle. The two top flaps that form the handle often feature tabs or tongues that lock into pre-cut slots on the side flaps, keeping the lid closed securely during handling and transport.
The outer surface is commonly laminated with coated paper such as couche, duplex, or ivory, and is suitable for high-resolution offset printing. Additional surface treatments—such as lamination, foil stamping, embossing, or spot UV—can be applied to enhance aesthetics and brand perception. Boxes are delivered flat-packed and are easily assembled by hand, making them suitable for small to medium production runs or promotional use.
When designing the handle, it’s important to maintain a minimum width of 15–20 mm to ensure comfort during carrying. Rounded corners are recommended to prevent paper tearing. For products with moderate to heavy weight, the handle area should be reinforced, either by increasing the handle width or by laminating additional board layers. Any locking mechanisms (e.g., tongue locks) must be precisely die-cut to allow easy but secure assembly.
Hộp Quai Xách Dây
The Rope Handle Box, also known as a Gable Top Box (屋顶箱 – commonly used in China), is a premium corrugated packaging solution featuring a pair of rope handles threaded through pre-punched holes on the box body or lid. The rope is securely knotted inside, forming a durable and portable carry handle—eliminating the need for an additional shopping bag. This box style blends functional portability with visual sophistication, making it ideal for products that require strong visual impact and branding at the point of sale.
Commonly used in sectors such as luxury gifts, premium cosmetics, wine packaging, specialty food, confectionery, and corporate gift sets, the rope handle box delivers both a convenient user experience and a high-end presentation. It also serves as an effective brand ambassador during promotional campaigns, festive seasons, or formal gifting occasions.
This box type is typically made from E-flute, F-flute, or EB double-wall corrugated board, laminated with coated paper such as couche, duplex, or ivory. The surface is usually offset printed and then laminated to enhance durability and elevate visual effects, while ensuring sharp image reproduction and structural integrity.
The handles are made from cotton, nylon, or recycled PP rope, with diameters ranging from 4–8 mm and load capacity between 2–8 kg. The punched handle holes are typically round and reinforced with metal eyelets for added durability and a refined appearance. Boxes are shipped flat-packed and can be easily assembled by hand upon use.
When designing the handle, hole size and placement must match the rope diameter and intended load capacity. Handle length should generally fall between 22–30 cm per side, offering a comfortable grip while remaining proportionate to the box dimensions. For heavier or fragile products, it is recommended to use thicker flute board, add reinforced bottom layers, or insert internal trays to distribute the load evenly. If adopting the gable-top lid structure popular in the Chinese market (屋顶), precision die-cutting is essential to ensure a tight, secure closure without compromising ease of opening.
Hộp Quai Xách Nhựa
The Plastic Handle Box is a corrugated packaging solution designed with a detachable plastic handle mounted on top of the box. The handle is inserted through two pre-cut slots along the top panel and is usually assembled after the main box structure is completed. This structure combines convenience, load-bearing strength, and reusability, making it ideal for packaging heavier products or those that require frequent handling or transport.
Common applications include electronics, children’s toys, canned or jarred food, premium Tet gift sets, wine, cosmetics, and corporate gifting kits. Thanks to its secure grip, reusable functionality, and premium appearance, this box style is a favorite in retail-ready packaging and promotional gifting campaigns where brand impact at the point of sale matters.
The box body is typically made from E-flute, F-flute, B-flute, or multi-wall corrugated board (3 to 7 layers) depending on the required load capacity. The outer surface is laminated with couche, ivory, or duplex paper to support high-resolution offset printing and post-print enhancements such as lamination, spot UV, foil stamping, embossing, or textured UV finishes.
The handle is made from materials like PVC, PP, HDPE, or recycled plastics, with customizable dimensions and styles. Typical load capacities range from 0.5 kg to 15 kg, depending on the handle specification. Boxes are delivered flat-packed, compatible with both manual and automated packing lines, helping reduce warehousing and shipping costs.
To ensure durability, the handle slot dimensions must match the plastic handle design precisely—tight enough to lock in place, yet loose enough for smooth insertion. The handle should be centered along the top spine and reinforced using a plastic support plate (if required) to prevent tearing during transport. For heavier loads, use heavy-duty plastic handles and conduct real-world load testing before mass production to validate performance.
Each corrugated box type featured in this guide is compatible with a wide range of flute profiles and laminated papers such as couche, ivory, duplex, and kraft, offering maximum design flexibility and meeting a variety of packaging needs—from mass-market to premium segments.
At Newlifepack, we apply advanced offset printing technology using the “DIAMOND” KOMORI press, ensuring sharp imagery, vibrant color reproduction, and high consistency—even in high-volume production runs.
Beyond exceptional print quality, every packaging product from Newlifepack is meticulously finished with surface enhancements like foil stamping, embossing, UV coating, lamination, and metalized film application. These effects not only enhance visual appeal and durability, but also strengthen brand recognition at every touchpoint.
Choosing the right box style doesn’t just streamline production costs—it creates a memorable unboxing experience that helps your brand stand out, connect with consumers, and add lasting value in an increasingly competitive marketplace.
With over 17 years of experience serving top-tier brands across consumer goods, food & beverage, and luxury product sectors, Newlifepack doesn’t just print beautifully—we create packaging solutions that help brands shine from the very first glance.
Thank you for considering us among the many packaging and printing providers. We’re excited for the opportunity to work with you!
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