Short answer
Choose your box in three steps: measure the product and add 5 to 10 mm clearance per side for the internal size, pick single wall up to about 15 kg and double wall above that or for palletised and export loads, then pick the style (0201 for general shipping, 0427 for retail-ready mailers, 0409 for long or flat items).
Step 1: get the internal size right
Box dimensions are always quoted as internal length x width x depth, in that order. Measure your product at its widest points, then add 5 to 10 mm per side for clearance, plus the thickness of any cushioning. A box that is too big costs twice: once in board, and again in void fill and carriage.
Step 2: match the board to the weight and journey
| Load | Typical board | Why |
|---|---|---|
| Up to 5 kg, short journey | Single wall B or E flute | Light, neat, good print surface |
| 5 to 15 kg, parcel network | Single wall C flute | Best cushioning per pound spent |
| 15 to 30 kg, palletised | Double wall BC flute | Far better stacking strength |
| 30 kg plus, export | Heavy duty double or triple wall | Compression and puncture resistance |
Step 3: choose the style
- 0201 regular slotted case: the default shipping box, taped top and bottom.
- 0427 die cut mailer: tuck-in lid, tidy presentation, no tape needed on the base.
- 0409 die cut tray or wrap: ideal for flat, long or awkward items.
- 0300 telescopic lid and base: for tall, heavy or fragile products.
If you are not sure, sample it
We make corrugated boxes to your exact internal size in Letchworth, so a bespoke box is rarely more expensive than a stock box you have to fill with air. Send us the product dimensions, or the product itself, and we will make a free sample you can pack and drop test before you commit.
Frequently asked questions
- What is the minimum order for a bespoke box?
- There is no minimum on stock lines, and bespoke corrugated runs can start from as little as one, but we will advise the most cost efficient run rate depending on size and board grade.
- How do I measure a box?
- Always internal length x width x depth. Measure the product, add 5 to 10 mm clearance per side, then add cushioning thickness.
- Can I get a sample before ordering?
- Yes. We produce free samples on our own box-making machines so you can test fit and drop performance first.
Think your packaging is bigger than it needs to be?
Send us your product dimensions and we’ll come back with a right-sized option. There is no minimum on stock lines, and bespoke corrugated runs can start from as little as one, but we will advise the most cost efficient run rate depending on size and board grade.
Request a QuoteRelated pages
Subscribe to our blog
One email a month with our latest packaging guides, compliance updates and sector notes. No sales pitches, and you can unsubscribe any time.