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Custom Printed Corrugated Boxes
Custom Corrugated Boxes
SunTop Printing manufactures custom printed corrugated boxes for commercial mailer, retail, and transit packaging in custom sizes, flute profiles, and corrugated constructions.
Production includes litho-laminated corrugated boxes with offset-printed face paper, custom mailer boxes, retail corrugated boxes, and other printed corrugated packaging. Box dimensions, flute, corrugated construction, printed surface, and required strength are matched so the print and corrugated structure work together in the formed box.
Printed Corrugated Boxes
For printed corrugated boxes, the printed surface has to remain flat, clear, and intact after the face stock is mounted to corrugated board and the box is die cut, creased, folded, and formed.
SunTop Printing produces A, B, C, E, F, AB, BC, and microflute corrugated boxes. Kraftliner and coated white-top liner are used as liner options across corrugated constructions according to the required printed surface and board strength. For applicable litho-laminated boxes, printed face stocks such as CCNB are mounted to the corrugated board before die cutting, creasing, folding, and forming. Where recycled-fiber content is specified, it is matched to the face stock, fluted medium, flute profile, and required board strength.
E-flute, F-flute, and other microflute constructions provide a finer corrugated profile for mailer and retail boxes with printed face stock mounted to corrugated board, while the broader flute range supports different strength and transit requirements.
Among SunTop Printing’s completed commercial corrugated-box orders, one comprised 180,000 F-flute litho-laminated retail corrugated boxes using 300 gsm coated offset-printed face paper, full-coverage CMYK printing, and matte anti-scuff lamination.
Continuous graphics extended across adjacent panels with alignment held within ≤0.6 mm. The main printed panels remained flat and the graphics remained clear, with washboarding and flute read-through controlled so they did not interfere with the printed image. The matte anti-scuff lamination remained intact after creasing and folding.
After mounting and forming, the printed face remains bonded to the corrugated board across the main panels, edges, and crease positions, while lamination or coating remains intact through creasing, folding, and surface friction.
A litho-laminated printed surface tested on a Sutherland® 2000™ Rub Tester to ASTM D5264 retained the printed surface and lamination after 100 cycles under a 4 lb load.
Corrugated Box Orders
One commercial corrugated-box order completed by SunTop Printing comprised 480,000 E-flute litho-laminated corrugated mailer boxes across eight printed artworks. All eight used the same corrugated structure, dieline, E-flute board, crease positions, formed dimensions, panel proportions, and die-cut / crease relationships.
Before commercial production, SunTop Printing uses a Kongsberg C64 to make a full-size corrugated-box sample from the dieline and check formed dimensions, crease positions, closure, and box-forming result.
Across commercial production, printed graphics stay aligned with the die-cut and crease positions while formed dimensions remain within the required range. Die-cut registration tolerance is ±1.0 mm, while litho-laminated production has achieved ±0.5 mm optical registration between printed graphics and die-cut / crease positions on the formed box.
Completed E-flute mailer-box results include inside dimensions of 0 to +2 mm, outside dimensions of 0 to −2 mm, and slotting-depth error of ≤1 mm.
One commercial E-flute corrugated board tested to ISO 3037 achieved ECT ≥5.5 kN/m using a ZwickRoell zwickiLine and ECT Compression Test Kit.
For handling and distribution, completed corrugated-box results cover compression, loaded drops, third-party distribution testing, and prolonged sea transit.
One litho-laminated E-flute mailer box reached a 1,500 N maximum BCT load, with 8.0 mm deformation at maximum load. A separate E-flute mailer box, after 24 hours at 20°C and 65% RH, completed 10 loaded drops from 76 cm—one corner, three edges, and six faces—while retaining its box structure.
A commercial E-flute litho-laminated corrugated mailer box completed third-party ISTA 3A testing in loaded condition; after testing, the outer box remained closed, the main panels retained their formed shape, and the die-cut and crease positions remained functional. In a separate commercial result, the bottom boxes retained their shape and stacking condition after 30 days of sea transit and eight-high stacking.
Custom Corrugated Box Manufacturer
SunTop Printing manufactures custom printed corrugated boxes as part of its broader Custom Printed Boxes production, with the key printing and converting stages completed in house.
For corrugated boxes with offset-printed face paper or printed liner mounted to corrugated board, SunTop remains responsible for the key production stages from printing through mounting, die cutting and creasing, and folding and gluing for applicable box structures.
The production flow uses the HEIDELBERG Speedmaster XL 162 for corrugated-box face paper and printed liners at sheet sizes up to 1210 × 1620 mm, followed by the BOBST MASTERFLUTE 170 for mounting the printed face to corrugated board. The BOBST MASTERCUT 1.65 PER handles die cutting and creasing of mounted corrugated board at sizes up to 1650 × 1300 mm, with the BOBST VISIONFOLD 110 handling folding and gluing for applicable structures.
For applicable litho-laminated mailer and retail corrugated boxes, monthly production capacity is 15,000,000 boxes.
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