How Tuck Packaging Boxes are Manufactured? A Comprehensive Guide!

To many people, almost every paper-based packaging looks the same. However, there are tons of differences that someone from the packaging and manufacturing industry can spot at a glance. Tuck boxes are one of the most common paper-based packaging available in the market. This blog explores how tuck boxes are manufactured and why your business can benefit from using these packaging boxes for your products. Read on to learn more about these boxes. 

What is a Custom Tuck Box?

Tuck boxes are a type of packaging that uses flaps. These flaps are tucked inside the boxes and create a strong closing mechanism. Most businesses use these boxes when opting for retail for several reasons. One of the major advantages of using these boxes is that the product remains inside the box even when it is placed upside down. 

What Materials are Used to Make Tuck Boxes?

Before we explore how the boxes are manufactured from scratch, let’s have a look at the two common materials used in their manufacture. Most businesses prefer paper-based packaging for manufacturing their tuck boxes. You can have a look at the following  two materials commonly used for tuck boxes:

• Cardboard 

Cardboard is a lightweight and cost-effective material used for tuck boxes. These boxes can be customized in different sizes, designs, and colors. You can add windows to your cardboard boxes so customers can have a look at the products. These boxes protect the products from dust and water to a certain degree. 

• Corrugated Cardboard

Another common material used for tuck boxes is corrugated cardboard packaging. This material is also lightweight and cost-effective, but offers more protection than regular cardboard boxes. The corrugated cardboard boxes have three layers: two cardboard layers on the outside and a corrugated flute inside. You can find the following flutes to add within the cardboard layers:

• A flute is approximately 5mm thick
• C flute is approximately 4mm thick
• B flute is approximately 3.2mm thick
• E flute is approximately 1.59mm thick
• F flute is approximately 0.79mm thick

Is Kraft Packaging Used for Tuck Boxes?

Yes, you can use Kraft packaging for tuck boxes, but only when you are packing lightweight items. For instance, if you are packing trinkets or lightweight jewelry like earrings or rings, Kraft tuck boxes are an ideal solution. These boxes can keep the products safe from dust and humidity. They are also lightweight and cost-effective. You can keep the natural brown of the Kraft or bleach it and then dye it to get different colors. 

Pulp Preparation for Cardboard and Corrugated Cardboard

The first step is to prepare the pulp to make the cardboard sheets. The tree barks are stripped and chipped into smaller pieces; from there, they are cooked to form a mixture. An important point to note here is that the US plants more trees than it harvests every year, which helps in maintaining the balance. The mixture is then processed further to make paper by pressing and drying. 

Preparation of Corrugated Sheets  

The prepared sheets you get are called cardboard, and they are used in corrugated cardboard boxes as well. However, a small change in corrugated cardboard is the flute added inside. To prepare these flutes, the processed paper is passed through a corrugator, a special type of roller with fluted lining. Commonly, there are around five types of corrugator rollers, each offering a different type of corrugated flute. These corrugated flutes are pressed between the two cardboard layers to make tuck boxes.

Die-Cutting of the Tuck Boxes

The process before die-cutting is the same for every manufacturing unit. The die-cutting, however, is different for every manufacturer, because of the custom requirements of every business. Manufacturers only proceed with the die-cutting of tuck boxes when they have a custom order. Businesses provide manufacturers with the custom sizes and styles, which are then used to cut the boxes according to the requirements. Specialized machines and techniques are used to cut the boxes according to the needs. If a box has an additional die-cut on the side or top of the box, that is also carried out in this process.

Printing of the Boxes 

After the boxes are cut to the sizes and shapes as asked by the businesses, the next process is printing the boxes. When you are placing your order with any manufacturer, you can ask about the type of printing they use. Other than printing, there are three important aspects of customization that are used in the process of printing. Have a look at these three custom aspects of printing:

• Designs for your Tuck Boxes

Designs are an important part of printing because they help your brand create a unique identity in the market. On the surface, it's the packaging box that has to stand apart from the competitor, so you can get more customers. You can choose various types and techniques of designs for your tuck boxes, like minimalist, geometric, rustic, textured, etc. 

However, if you feel like you are stuck and cannot come up with compelling designs, The Customize Boxes is here to help. With our free design support, you can have experts help you with the designs without any costs. You can look at the free 3D mockups before you finalize the order. 

• Colors to Boost Visibility 

Choosing colors for your tuck boxes is essential, and it plays a major role in attracting sales and boosting visibility. Nobody would notice a hideous packaging in dull shades next to funky colors. This is why you must do your competitor research before choosing the colors for your boxes. You can keep in mind your brand’s persona when deciding on the colors or the nature of the products you are packaging. 

For instance, if it’s a kids’ product, choosing funky colors like bright shades of orange, red, yellow, and green would work best. However, if you are packing serums, makeup brushes, or even soap bars, opting for pastels like powder blue, sage green, lime yellow, champagne pink, etc., would work perfectly.

• Finishes for a Premium Feel

After the colors and designs are decided, the next important step is to choose the finishes. These finishes are like the cherry on top of a cake; they enhance the overall look of the tuck boxes. There are many finishes you can use on your customized tuck box packaging. Whether you want to use one or more depends on your design, the placement of the boxes, and your preferences. 

You can use matte to give the boxes a subdued look, and soft-touch when you want an additional velvety touch to the subdued boxes. If you go with the gloss finish, the tuck boxes get a shiny and protective layer around them. Foiling in red, blue, green, purple, silver, and gold provides a refined and luxurious visual appeal. You can also use embossing to give a raised effect to the visuals on your tuck packaging boxes.

Shipping Tuck Boxes to the Warehouse

Once the order is finalized, it is sent for manufacturing, and after the order is processed, the manufacturers ship it to the destinations. When it comes to custom packaging, it is often businesses that need the services. This means the last point is from the manufacturing unit to the warehouse of a business. 

But not every business has a giant warehouse; some are operating from their garage, and they can order as long as they go for the minimum order quantity as described by the manufacturer. For TCB USA, we have an MOQ of 100 boxes.

What Industries Use Tuck Boxes?

Now that you know the whole process of manufacturing, it’s time to have a look at the industries using these boxes. Whether you are operating as B2B or B2C, you can use these tuck boxes for your packaging. Small, mid to enterprise-level businesses use tuck boxes for their products because they know the visual appeal and functionality these boxes offer. Have a look at some common industries using these boxes: 

• Game & Toy Industry

The gaming industry uses the tuck boxes for different products. You can see different toys and board games packed inside tuck boxes. Most brands use playing card tuck boxes because they know that the flaps will ensure safety for each card. You can use these boxes to pack different gaming products. 

• Soap Industry 

Besides using shrink wrap for the soap bars, businesses use tuck boxes in various styles when opting for retail. You can design the boxes in different ways and even add a window cut-out so customers can have a look at your product before purchasing it. 

• Automobile Industry 

Most automobile parts are packed in tuck-end boxes and shipped to retailers and suppliers. While these boxes are lightweight, they do protect products like nuts and bolts just the same. You can get these automobile boxes in various sizes and with your brand’s logo. 

• CBD Industry

If you are a business selling CBD products, you can choose tuck packaging boxes in various sizes and styles. Whether you are packing oil or any other product, choosing these boxes ensures product safety even when the boxes are placed upside down or fall to the ground. 

What are Some Common Styles of Tuck Boxes?

Tuck boxes come in a variety of styles. You can explore these styles and choose the ones that best serve your needs. While every tuck box comes with flaps, it’s their positioning that decides the type of box. Let’s have a look at a few common styles of tuck boxes for your business: 

• Straight Tuck Boxes 

Straight tuck-end boxes are the ones that have flaps on the top and bottom of the box. These flaps are tucked on the same side of the box; hence, they are called the straight tuck boxes. Some common sizes you can find in these boxes are 2.3” x 1.4” x 5” and 8” x 2.4” x 5”. 

• Reverse Tuck Boxes

Reverse tuck boxes have flaps on two sides, but they are tucked on opposite sides. This means that if the top flap is tucked on the front side, the bottom flaps will be tucked on the back side, and vice versa. You can find common sizes in these boxes with 4.4” x 3.2” x 7” and 5” x 1.5 x 4.7” dimensions.

• Snap Bottom Tuck Boxes

Snap bottom features four interlocking bottom flaps and requires extra steps for assembly than an auto bottom box. These four flaps are snapped together to give a robust structure to the packaging box. Commonly, you can find sizes like 3.5” x 2.5” x 4”, and 4.2” x 3.3” x 4”. 

• Roll-End Tuck Boxes

Roll-end tuck style offers rolled flaps on the top and bottom of the box for more protection. You can use these boxes to pack items like books, artwork, ceramics, and customized mugs. A few sizes you can find in this style are 3” x 7” x 2.5” and 4.3” x 6.6” x 3.3”.

How Your Business Can Benefit from Tuck Boxes?

Are you still confused whether you should be using tuck boxes for your products or some other box? Whether the box is paper-based or not, it offers some sort of benefit to the business. Let’s have a look at a few benefits of tuck boxes offer, so you can decide better: 

• Durability

Since these boxes are usually made from cardboard and corrugated cardboard, these boxes can protect the products in a better way. The corrugated cardboard offers three layers of protection and keeps the products safe from water, dust, and pressure. Unless your boxes are exposed to heavy rainfall and pressure, they will keep the product safe. 

• Compact Storage

Tuck boxes are the best choice for businesses dealing with short storage space. The reason lies in their easy storage. You can get these boxes shipped flat. They are very easy to assemble and can be put together in a matter of seconds. Another advantage of having tuck boxes is that they won’t be damaged during shipping when laid flat on top of one another.

• Affordable Purchasing and Shipping

Paper-based packaging is mostly cost-effective, and tuck boxes fall under the same category. You can purchase them while not spending a fortune on the packaging. This means that even with the product added inside, the boxes won’t weigh as much as a rigid box would. You can save on shipping costs as well as the purchasing costs. 

• Perfect for Sending PR Packages 

Mailer boxes are a type of tuck box that most businesses use, regardless of the industry. You can see these boxes in makeup, home decor, gaming, technology, health, and skincare industries. These boxes are the perfect solution when you need to send a PR package to an influencer. You can get mailer boxes in different sizes and even styles. Whether you need printed mailer boxes or boxes with one color, we are here to help. 

How to Offer Better Cushioning to Products in Tuck Boxes?

Businesses can predict a smooth supply chain, but they cannot always guarantee it. Several unprecedented circumstances can occur. This is the reason brands choose to add inserts to offer cushioning to the products. You can also add the following inserts inside the tuck packaging boxes:

• Foam

Choosing the foam inserts adds a classy look to the product packed within the boxes, in addition to the cushioning. You can choose various colors of foam, like pale yellow or black. Most businesses selling watches and jewelry use foam as inserts for a luxurious visual appeal with added protection. 

• Plastic 

Plastic is another type of insert you can add inside your tuck boxes. Most businesses use plastic when they are adding somewhat lightweight and non-fragile items. You can use plastic inserts when packing serum bottles made of plastic. 

• Cardboard 

Packaging inserts made of cardboard are very common among businesses. If you are looking to be an eco-safe brand, choosing cardboard inserts is a great option. You can choose the desired thickness for the cardboard inserts and even get them designed in different ways.  

How Can You Enhance the Unboxing Experience for Customers?

Are you looking for ways to charm your customers? Adding more than just your products in a box can do that. There are different ways you can enhance the unboxing experience of customers and leave a lasting impression on them. Let’s have a look at three ways to achieve that:

 Add Colored Shredded Paper Inside 

Whether you are sending PR packages or just sending your product to customers, adding colored shredded paper will enhance the unboxing experience. You can use various colors for the shredded paper and add them inside the boxes. Another use of shredded colored paper is that it offers a bit of cushioning to products as well. 

• Choose Printed Stickers to Add Inside 

Are you sending makeup or cosmetic products to customers, or perhaps you are sending stationery items? Adding printed stickers inside the boxes will give your brand extra points because customers love it when businesses send them some freebies. If your brand can afford to send a few stickers with every order, adding these will be a plus point for your brand.

• Use Ribbons on the Boxes

Are you offering monochromatic boxes with your band’s logo? Adding printed or plain ribbons to the boxes will then be a perfect idea. You can give your tuck boxes a timeless and elegant look with these ribbons. Tie them in a bow or glue them to the boxes, whatever you prefer. You can get contrasting colors for the ribbons to give a more beautiful visual appeal to the boxes.

Why Choose The Customized Boxes?

Choosing an expert packaging manufacturer means more than just getting high-end boxes. Every business needs perks when they are ordering custom packaging. This is where we come, with a number of perks, businesses get high-quality packaging and save money as well. You can have the following perks when you place an order here:

• No die and plate charges
• Minimum order quantity of 100 boxes
• Free design consultation
• Free 3D mockups
• Discounts on bulk purchases 
• Free shipping in the US

Contact us today and learn more about our services. Or if you know the quantity of boxes you need with other specifications, you get a free custom quote as well.