Shipping case design parameters

Shipping Cases - Secondary Packages - ASTM D5118

R.S.C. - 0201 - The most common form of shipping container is the Regular Slotted Container - FEFCO 0201. Below are some guidelines for the construction of a good R.S.C. container:

  1. R.S.C. standard flaps. Gaps on the top and bottom flaps should not exceed 1/8" (3mm) when taped. Gapping flap options should not normally exceed 1/4" (6mm). A small gap in the flaps is often required for case sealing machinery. A gapping flap style is sometimes referred to as an 0209 rather than a 0201.
  2. Manufacturer’s joint can be glued, taped or stitched. Gluing is the most common method and preferred except on very heavy boxes (above 65# - 30Kg). Staples used in stitching must be rust resistant, and normally no more that 2" (55mm) apart and no more than 1" (25mm) from the ends of the joint. Tape used for the manufacture's join should be of sufficient width and of the reinforced type.
  3. The manufacturer's joint may be attached to either length or width panel, but some case erection machinery can require a particular arrangement of the panels.
  4. Minimum manufacturer's joint size that we would recommend is 1" (25mm) with 1.25" (30mm) being a preferable minimum figure. The joint must be initially cut not more than 3/16" (5mm) below the scoreline on the top and bottom of the box. When the Extended Glue-flap option is chosen, the extended flap must also be glued to the flaps of the box. The purpose of glue lap extensions is to strengthen the joint of a glued case. They are typically used for all single walled glued cases, particularly those with a depth less than 1' (305mm)
  5. Adhesive must be waterproof upon setting. Bond must extend at least 90% of the length of the joint and have a minimum of 85% fiber tear.
  6. Tolerances are +/- 1/8" (3mm) on all scoring dimensions for boxes >20" (55mm) sum of L+W+D. Tolerances are +/- 1/16" (1.5mm) for boxes with L+W+D <20" (55mm).
  7. Maximum expected board wrap tolerances should be 2% in the overall net size for machine erected cases and 4% in the overall net size for hand erected cases.
  8. Styles - FEFCOThe European Federation of Corrugated Board Manufacturers was created in 1952. Its headquarters are situated in Paris and the Federation is governed by French Law. Today FEFCO has 20 Active Members from 20 Associations of Corrugated Board Manufacturers in Europe.

Description of basic type groups (The terms Box and Case are interchangeable in the context of these descriptions.)

02 - Slotted-type boxes consist of basically one piece with a stitched, taped or glued manufacturer's joint and top and bottom flaps. They are shipped flat, ready to use and require closing using the flaps provided.

03 - Telescope-type boxes consist of more than one piece and are characterized by a lid and/or bottom telescoping over the body of the box.

04 - Folder-type boxes usually consist of only one piece of board. The bottom of the box is hinged to form two or all side walls and the cover. The boxes can be set up without stitching or taping. Locking tabs, handles, display panels etc., can be incorporated in the design.

05 - Slide-type boxes consist of several pieces of liners and sleeves sliding in different directions into each other. This group also includes outside sleeves for other cases.

06 - Rigid-type boxes consist of two separate end pieces and a body and require stitching or a similar operation before they can be used.

07 - Ready-glued cases consist of basically one piece, are shipped flat and ready to use by simple setting up.

09 - Interior fitments such as inside liners, pads, partitions, dividers, etc.


Material Slotted Containers Telescope Folders Slide Boxes Rigid-type Boxes Ready Glued Cases Interior Fitments
0100-0110 0200-0209 0300-0309 0400-0409 0501-0509 0601-0608 0700-0703 0900-0909
  0210-0218 0310-0314 0410-0416 0510-0512 0610-0616 0711-0718 0910-0914
  0225-0229 0320-0325 0420-0429   0620-0621 0747-0748 0920-0929
  0230-0231 0330-0331 0430-0437     0751-0759 0930-0935
    0350-0351 0440-0447     0760-0761 0933 Divs.
      0450-0459     0770-0774 0940 - 0976
      0460       0980-

Case Terminology - A cross-reference section is provided in order to aid in communication as terminology can vary even between different groups within the same company. FEFCO standards are widely use in Europe and have gained some acceptance in the US; they offer one good way of reducing the "tower of Baybel" effect.

It is impossible to list all of the terms used to describe pack designs. Here, however, are listed some of the terms more frequently used. FEFCO number codes should be used to describe a case wherever possible to stop any possible confusion.

Some of the FEFCO designs have no frequently used name, so the most general terms of die-cut tray or die-cut folder is given. It should be noted that some designs have names relating to their use. This does not mean these designs are not frequently used for other purposes.