Custom Large Cardboard Boxes

Boxes for Bulky Products

For retailers and manufacturers, a large box needs to fit the product snugly and protect its weak points. Flat-pack furniture needs long, shallow cartons with edge protection. Rugs and rolled goods need long boxes with a square cross-section. Lamps, mirrors and pictures need inserts or corner protectors so the fragile parts never touch the box wall.

Tell us the product dimensions and weight, how it will be shipped and whether it goes on a pallet or through a parcel network. Pallet deliveries are gentler, while parcel networks involve conveyor belts, drops and stacking, so boxes going by courier often need a stronger board grade than those going by pallet.

Large items often need some form of internal protection. Corrugated corner pieces, edge strips and pads cut from the same board keep a table top or a framed mirror away from the walls, so a knock to the outside of the box does not reach the product. For lamps and items with fragile parts, a die-cut insert can hold the base and shade separately. Using board for these parts rather than foam or polystyrene keeps the whole package in one material, which customers find easier to deal with once it has arrived. p2 Long cartons for rugs and poles are covered on our long postal tubes page as an alternative.

Choosing Board Strength

Single wall corrugated is lighter and cheaper, and fine for large boxes holding light contents such as bedding, packaging materials or lightweight products. Double wall corrugated has two layers of fluting and is the right choice for heavier contents, long journeys and boxes that will be stacked. Triple wall board is available on request for very heavy items and industrial use.

Large boxes flex more than small ones, because there is more unsupported wall. If your box is tall or long, double wall board is usually worth the small extra cost. We can also add internal partitions, which divide the box and stiffen its walls at the same time.

Weight limits matter for people as well as boxes. A very large box filled with books becomes too heavy for one person to lift safely, which is why removals firms keep their heaviest contents in the smallest boxes. If you are choosing a size range, match each box to the kind of contents it will carry rather than simply offering bigger and bigger cartons. p2 The grades are explained in the guide to board and card types.

Handles, Closures and Extras

Hand holes cut into the ends make large boxes much easier to carry, especially when full. For heavier items, reinforced hand holes with an extra layer of board prevent tearing. Some customers prefer a carry handle made from rope or plastic for awkward items such as garden equipment.

Most large boxes close with the standard four flap top and bottom, taped along the seams. For products that will be opened and closed repeatedly, a full overlap carton or a telescope style with a separate lid may be more practical. Tear strips make opening safer for customers, avoiding the need for a knife that could damage the product inside. p1 Lids that lift off are shown on our half slotted containers page.

Printing Large Cardboard Boxes

Large boxes give you a big canvas. One or two colour flexo printing on brown kraft is the most economical way to add your logo, phone number and handling marks such as this way up arrows, fragile warnings or weight guidance. For premium products, full colour printing on white board makes the box part of the brand experience.

For removals boxes, consider a write-on panel on each side with lines for the room, contents and box number. It is a simple addition that customers find genuinely useful, and it makes your boxes the ones they recommend to friends who are moving.

Tell Us the Load and the Journey, Then the Size

A large box is specified by what it carries and how it travels, and the dimensions come last. A 600 mm cube of bedding on a pallet is single wall; the same cube of books through a parcel network is double wall with reinforced hand holes, and nobody should be lifting it anyway. So send the heaviest contents in kilograms, say pallet or courier, and tell us how high the boxes will be stacked; then give the inside size you need.

Removals firms should settle on four sizes and keep the heaviest contents in the smallest box. Say if a write-on room panel or a phone number goes on the sides. The custom quote arrives by email within one working day, with the minimum set per job so a depot can order one size at a time.

The free proof shows the flat blank with print and hand-hole positions. Production takes 4 to 7 working days after approval and the bundled flat boxes reach UK mainland addresses, depots included, by free tracked delivery. Firms that also supply packing materials usually add bubble wrap rolls for fragile items to the same order.