Folding Cartons 101: A Beginner's Guide to 7 Essential Styles

French Reverse Tuck Carton (FRT)

The French reverse tuck carton is one of the most commonly manufactured styles due to its versatility. This design features end tucks that close on opposite sides: the top flap closes into the back, while the bottom flap closes into the front. The top can be secured with either a slit lock or friction tuck closure.

French reverse tuck cartons are suitable for both machine automation and hand-filling, making them ideal for light to medium-weight products such as cosmetics and pharmaceuticals. Their economically nested shape makes them cost-effective for manufacturing. However, the bottom tuck flap, which closes from back to front, reveals an raw edge when assembled that some may find unattractive.

French Straight Tuck Carton (FST)

Also known as – tube with tuck end closures

A French straight tuck carton features end tuck closures on both the top and bottom that close to the same side (front to back). The top can be secured with either a slit lock or friction tuck closure. A friction tuck closure offers a cleaner appearance but is less secure than a slit lock closure, which provides added strength and security. The bottom always has a slit lock closure to ensure product safety.

Similar to the French reverse tuck (FRT) style, straight tuck cartons are suitable for both machine automation and hand-filling, making them ideal for light to medium-weight products such as cosmetics and pharmaceuticals. One potential drawback is their inefficiency in nesting compared to reverse tuck cartons during manufacturing, resulting in slightly higher board usage.

Tuck Top Auto Bottom Carton (TTAB)

Also known as –  automatic bottom, crash bottom, auto-bottom, auto-lock bottom, auto erecting carton

An auto-bottom carton features a tuck top and a bottom with extra glued flaps that automatically erect when opened. This design is ideal for hand-filling, as it simplifies the assembly process compared to a traditional tuck carton. It is sturdy and durable, making it suitable for heavy products like candles and liquor, as well as lower-volume applications where quick hand assembly is crucial. Although the additional glue lines for an auto-bottom carton increase manufacturing costs, these can be offset by reduced labor costs due to faster assembly.

1-2-3 Bottom Carton

Also known as – houghland bottom, snap bottom, lock bottom

A 1-2-3 bottom carton features a tuck top and a bottom that folds in three easy steps, giving it its name. Its unique design offers greater strength than a standard tuck carton, enhancing product security in retail settings. When displayed on a shelf, the bottom shows no raw edges, ensuring a clean and professional appearance. It is ideal for heavier products and countertop displays.

Seal End Carton

Also known as – full overlap seal end, machine glued end

A seal-end carton has four similar-looking flaps that fold inward to create a sturdy closure at both the top and bottom. These cartons are typically filled using automated equipment, making them easy to assemble and seal with machinery. This style is not recommended for hand filling, as it requires the application of glue or tape for closure. Seal-end cartons are ideal for medium to heavy products, machine-filled and sealed cartons, and powdery items, as the flaps help make them sift-resistant.

Sleeve

Also known as – open ended tube

A sleeve is a slip-on tube, essentially a box without a top or bottom. It is easy to glue and assemble and is made from an economical rectangular blank size with minimal waste. This style is the most cost-effective due to its lower material usage. However, a sleeve does not offer independent protection for the product; it is designed to cover the graphics of an existing carton or serve as a slipcover for a two-piece tray assembly.  In some cases, the sleeves may need to be secured with wafer seals to keep from falling off.

Simplex Tray

Also known as – double sidewall tray, double endwall tray

A simplex tray is a paper-based alternative to rigid setup boxes, commonly used for premium items or board game boxes. These trays offer excellent presentation and enhance the perceived quality of products like jewelry or gift sets. Unlike rigid boxes, simplex trays can be shipped flat, saving on warehouse storage space. However, a tray requires an additional packaging component, such as a lid or sleeve, to secure the product. While a simplex tray provides a cost-effective solution, it is not as durable as a traditional setup box and requires moderate assembly.