Custom Auto Lock Bottom Boxes

Sizing and Inserts

Size the box from the inside, around the product as it will be packed. For a jar or bottle, measure the diameter at the widest point and the full height including the lid or pump. Allow a couple of millimetres each side for easy filling. If the product is glass, a little more room for an insert or a wrap is sensible.

Inserts keep tall or round products upright and stop them knocking against the walls. A simple card collar holds a jar at the shoulder; a divider grid separates bottles in a set. Because the crash-lock base is flat once locked, inserts sit level on it and do not rock.

Weight also affects size. A heavy product presses down on the base and outwards on the side panels, so a box sized right to the millimetre may bow slightly when lifted. For anything over half a kilo, we usually add a fraction more board thickness rather than more space, which keeps the fit snug and the walls straight. If you are unsure, tell us the weight along with the size and we will suggest a grade. Our step-by-step guide to measuring products covers jars and bottles in more detail.

For gift sets, think about the order in which items go in. A heavy jar should sit on the base at the back, with lighter items in front, so the box does not tip forward when picked up. Your insert can make that layout obvious to whoever is packing.

Board Choices

Most auto lock boxes are made from folding boxboard, usually in a heavier grade than you would use for a light tuck box. For products over a kilo or so, or for anything that will be posted on its own, E-flute corrugated board with a printed outer liner gives much better crush strength while still looking like a retail carton.

White board gives the cleanest print. Kraft board suits natural, craft and farm-shop products. Both can be printed inside as well as out.

• Heavy folding boxboard for retail shelves
• E-flute corrugated for heavier or posted products
• White, kraft or metallic-look board
• Inside print for an extra brand moment

Print and Finishing

These boxes print exactly like a standard folding carton, so you can use full colour, brand Pantones, foil, embossing and spot UV. The base panels are visible when the box is lifted, so some brands put a pattern or a short message underneath; others leave it plain to save on ink coverage.

If the box will be handled a lot, a matte or gloss laminate protects the print from scuffs and fingerprints. Soft-touch laminate gives a velvety feel that suits premium skincare and spirits. Foil works well on a logo or a product name and catches the eye from a distance on a shelf. A comparison of laminates and foils on our board and finish page shows what each one looks like on a carton.

Think about the order in which a shopper sees the panels. On a shelf, the front and one side are visible; in someone's hand, the top and back get read next. Put the product name and main promise on the front, the scent, flavour or variant on the side, and the detail and barcode on the back. That keeps every panel useful without crowding any of them.

Packing Line and Storage Tips

Auto lock boxes arrive flat and pre-glued, so there is nothing to assemble on the base. To set one up, hold the box by two opposite corners and push them towards each other; the base snaps into position. Drop the product in, close the top tuck and the box is finished. Square items such as candles often go in a cube box with a crash-lock base, which sets up the same way.

Store flat boxes in their cartons, on a shelf rather than the floor, and away from damp. Board that absorbs moisture can lose some of its spring, which makes the base lock less crisply. If you are running a machine packing line, send us its specifications so we can match the glue pattern and board grade to what the machine expects.

Weigh the Product Before You Pick a Board

The weight of the filled box decides more than its size does. Put the product on kitchen scales, including the jar, lid and any insert, and send that figure with the measurements: under half a kilo and heavy folding boxboard will do, above it we move to a thicker grade or E-flute, and for anything posted on its own we lean towards corrugated every time. If the box is for a gift set, weigh the whole set, not the heaviest item.

Decide the top closure next. A straight tuck is quickest to close by hand; a reverse tuck suits machine lines. If the crash-lock base turns out to be more than the product needs, tuck end auto bottom cartons are the lighter sibling and we can quote both. Send the product dimensions, weight, quantity and artwork and a custom quote comes back by email within one working day, followed by a free proof showing the dieline and base. Printing takes 4–7 working days after approval, free tracked delivery to UK mainland addresses takes 2–3 working days, and boxes that arrive misprinted or crushed are reprinted or refunded when reported within 10 days.