If you are considering folding cartons for your product but aren’t quite sure where to start or need some support – you are not alone. From tuck ends and crash-lock bases to textured materials and foil finishes, there are countless options available. Folding cartons offer a customisable, cost-effective, and sustainable way to spruce up your packaging – but knowing what to ask for is half the battle.
In this blog, we will walk you through the key carton styles, materials, sizes, and finishes to help you choose the best solution for your product.
What are folding cartons?
Folding cartons are lightweight paperboard boxes that are printed, die-cut, folded, and glued to create compact and attractive packaging for a wide range of products. You will find them everywhere — from cosmetics and food products to pharmaceuticals and personal care.
Unlike rigid boxes, folding cartons are delivered flat for assembly, filling and closing. They offer endless possibilities for custom branding, structural creativity, and finishing touches.
Carton closure styles: which is right for your product?
The structure of your folding carton affects both function and appearance. Here are some of the most common styles we offer:
Straight Tuck End (STE)
Both flaps tuck in on the same side. Offers a clean front face and is great for products with a light to medium weight (e.g. cosmetics or supplements).
Reverse Tuck End (RTE)
One flap tucks at the top and the other at the bottom, opposite to each other. Slightly more cost-effective to produce and often used for smaller products.
Crash Lock / Auto-Lock Bottom
Designed for quick assembly and greater strength. The base locks automatically when the carton is popped open, ideal for heavier items like glass jars.
Seal End Cartons
Ends are glued shut, commonly used in pharmaceuticals or food packaging for tamper resistance.
Sleeve Cartons
A simple wrap-around sleeve without end closures. Great for showcasing inner packaging, bundling products, or adding a premium unboxing experience.
Custom Die-Cut Windows
Gives the end-user a glimpse of what is inside the box, adding intricacy to your packaging — popular in skincare, candles, and artisan food.
Choosing the right folding carton material
Your choice of board stock impacts not only the feel and finish of the carton but also its structural integrity and eco credentials. Some popular options include:
Folding Box Board (FBB): Available in different thicknesses and with various coating options (uncoated, single side coated, double side coated, with a double layer coating for increased whiteness) Lightweight but durable, often used for pharmaceuticals and cosmetics. Ideal for embossing.
Kraft Board: Brown or grey, natural-looking and ideal for eco-focused brands. Typically uncoated for a rustic aesthetic.
Recycled Board: Offers a sustainable option, though the surface may have slight variations in texture and colour.
Material weights are usually measured in GSM (grams per square metre) or microns. Heavier boards (300gsm+) are often chosen for premium products or to support heavier content.
Carton sizes & structure tips
When planning your carton, the three key dimensions to define are:
Length (left to right on the front panel)
Width (depth of the side panel)
Height (top to bottom)
Consider not only the size of the product but also how it will sit inside the carton — do you need an insert or internal support as product protection? Also, think about whether the carton needs to stack on shelves, fit into outer packaging, or meet postal requirements.
Custom sizing ensures a snug fit and minimises material waste, and your packaging looks much more professional as a result.
Finishing touches that make a difference
Folding cartons can be enhanced with a range of embellishments that add tactile appeal, luxury, and standout shelf presence:
- Embossing/Debossing – Raise or indent logos or patterns for a textured feel
- Foil Stamping – Add metallic shine with gold, silver, or custom foil colours
- Spot Varnish – Gloss highlights over specific areas of matte packaging
- Soft-Touch or Matt Laminate – A velvet finish that feels premium in the hand
- Die-Cut Windows or Openings – Showcase your product inside its outer packaging
These finishing options are particularly effective for premium products or when gifting appeal is important, and they elevate perceived value instantly.
Sustainability considerations
More brands are looking for environmentally responsible packaging solutions. Folding cartons can support your sustainability goals when produced, using:
- FSC-certified board
- Vegan toners
- Plastic-free window films or no windows at all
- Glue-less or minimal adhesive constructions
How Lotus Labels can help
Lotus Labels offers bespoke folding carton solutions backed by years of experience. Our state-of-the-art digital print and embellishment line paired with our folding and gluing machine allows us to deliver high-quality, custom-built cartons with precision and speed.
We will help you select the right style, size, board, and finishes to suit your product — and make sure your packaging looks beautiful and is structurally sound
Ready to Get Started?
Not sure what carton style fits your product best? Get in touch – we are happy to walk you through options or send you a sample pack.
