Industrial Parts Packaging Box Customization Case
Project Metrics
【Project Overview】
Industry: Industrial
Product: Mechanical equipment parts (metal processing parts/bearings/pipeline fittings)
Quantity: Multi-specification small batch initial + subsequent orders | Type: 5+ types
Material: Full white E-flute cardboard (1.5mm)
Process: Four-color printing + matte lamination + die cutting + paper card inner tray
Delivery time: Batch delivery after sample confirmation
【Client Background】
An industrial manufacturing enterprise mainly produces and exports mechanical equipment parts, with many single product specifications and large weight differences. Original packaging used universal cartons with foam/bubble wrap filling, requiring separate custom inner linings for different specifications, complex management. Filler loosening during transportation frequently caused part collision and scratches.
💬 Customer Needs
The client's original packaging method had high management costs: cartons with fillers required custom inner linings for each product, and when specifications exceeded 5 types, inner lining management became chaotic. Filler displacement during transportation caused metal parts to collide and scratch, leading to high return rates.
The client hoped to reduce management complexity through a unified packaging solution while ensuring transportation protection for different products. Initial order quantity was limited, making traditional plate-making printing costly.
Core demands: Multi-specification adaptation + Transportation protection + Simplified packaging management.
Project challenges:
✓ Many product specifications (5+ types) with large size and weight differences
✓ Filler displacement causing part collision and scratches during transportation
✓ Limited initial quantity, high plate-making costs
✓ Need one solution to fit multiple specifications
💡 Solution
A combination of bottom-lock boxes and airplane boxes is used, uniformly using full white E-flute cardboard (1.5mm). Custom paper card inner trays replace foam filling, with different specifications achieving differentiated fixation through inner tray slot positions.
Selection analysis:
Why choose bottom-lock box + airplane box combination?
Bottom-lock boxes have stable structure with self-locking bottoms providing good load-bearing capacity, suitable for medium-sized and heavier metal parts. Airplane boxes have large unfolded area and easy assembly, suitable for larger volume but lighter weight accessories. Both box types use the same corrugated cardboard specification, enabling unified purchasing and die cutting.
Why use paper card inner tray instead of foam/bubble wrap?
Foam and bubble wrap are consumable fillers requiring manual cutting and placement each time, with uncontrollable usage and high management costs. Paper card inner trays are die-cut with the box body in one pass, ready to fix products simply by placing into the box, improving operation efficiency with unified materials.
Why choose E-flute (1.5mm) instead of F-flute or B-flute?
E-flute achieves a good balance between thickness and cushioning. F-flute (2mm) is thicker, slightly wasteful for small and medium-sized parts packaging. B-flute (1.5mm) has similar protection but inferior surface printing quality compared to E-flute, as E-flute has more flutes (approximately 36 flutes/30cm), providing better printing support.
Why choose full white E-flute instead of yellow-core corrugated?
Export products have packaging appearance requirements. Yellow-core corrugated exposed at corners and inner surfaces affects product quality perception. Full white E-flute has white paper surface both inside and outside, with accurate printing colors, meeting export product packaging standards.
Production implementation and quality control:
① Measure each specification product dimensions → ② Design paper card inner tray structure (slot position positioning)
③ Sample confirmation (box type + inner tray compatibility) → ④ E-flute cardboard customization
⑤ Four-color printing + matte lamination → ⑥ Die cutting (box body + inner tray simultaneous die cutting)
⑦ Automatic box gluing/folding → ⑧ Inspection (box dimensions, inner tray positioning accuracy, printing content)
⑨ Sort by specification and ship
✅ Project Results
【Project Results】
【Delivery Data】
✓ Delivered products: Industrial parts packaging boxes (bottom-lock + airplane boxes + paper card inner trays)
✓ Material specifications: Full white E-flute cardboard (1.5mm)
✓ Covered specifications: 5+ different size parts unified packaging solution
✓ Printing method: Digital printing with zero plate cost
【Usage Effects】
✓ One packaging specification fits multiple products, reducing management workload
✓ Paper card inner tray fixation is firm, no obvious part displacement during transportation
✓ Bottom-lock box load-bearing performance meets expectations, no box damage
✓ Client placed subsequent orders
Case Summary:
Industrial parts often face packaging management difficulties due to numerous specifications and limited quantities per type. This case uses a combination of bottom-lock boxes and airplane boxes, uniformly using full white E-flute cardboard (1.5mm). Custom paper card inner trays replace foam filling to achieve precise positioning and fixation for different specification products. Paper card inner trays are die-cut with the box body in one pass, requiring no separate processing. Digital printing with zero plate cost makes initial small batch production economically viable, and unified cardboard specification procurement strategy reduces multi-product inventory management complexity.
Lexiang Experience:
Applicable scenarios: Multi-specification industrial parts packaging, export product packaging, foam filling replacement
Material recommendations: Choose E-flute (1.5mm) for small and medium-sized parts; choose F-flute (2.0mm) for heavier parts; choose B-flute (3.0mm) for stronger protection
Not applicable scenarios: Not suitable for precision instruments (recommend EVA inner tray or custom foam); not suitable for anti-static electronic parts (requires anti-static coating treatment)
Notes: Slot positioning accuracy of paper card inner trays directly affects fixation effectiveness, recommend designing slot shapes according to product contours and confirming by sampling
Professional Knowledge:
How to choose between paper card inner tray vs corrugated inner lining vs EVA inner tray?
Paper card inner tray: Lowest cost, die-cut with box body from same material in one pass. Suitable for regularly shaped metal and plastic parts.
Corrugated inner lining: Folded corrugated cardboard forming cushioning structure, suitable for gap filling and edge protection.
EVA inner tray: Mold-customized forming, best protection effect, suitable for precision instruments and high-value products. But requires mold cost, suitable for large batches.
Why choose Lexiang:
✓ Integrated solution of bottom-lock box + airplane box + paper card inner tray
✓ Paper card inner tray die-cut with box, no separate processing needed
✓ Small batch minimum order, flexible for new product trial production
✓ Full white E-flute suitable for export, good appearance quality
📸 📸 Results Gallery
❓ FAQ
What is the minimum order quantity for industrial parts packaging boxes?
Bottom-lock boxes and airplane boxes have a minimum order of 50-100 pieces for small batches. Paper card inner trays are die-cut with the box body, no separate minimum order.
Metal parts are heavy, can bottom-lock boxes handle the weight?
Bottom-lock box self-locking bottom structure provides stable load-bearing. Full white E-flute cardboard can support metal parts within 1-2kg. For over 2kg, recommend using F-flute (2.0mm) with inner tray fixation.
How is the protection effect after replacing foam with paper card inner tray?
Paper card inner trays precisely fix product positions through slotting. The most effective improvement over foam is solving the "filler displacement" problem - parts won't shake and collide during transportation. However, shock absorption is inferior to foam, recommend comprehensive consideration with outer shipping boxes.
Can multiple specification products share the same box type?
Yes. Unified box structure with only inner paper card tray slot positions adjusted, box external dimensions remain consistent. Uniform appearance packaging looks more neat and professional on customer shelves.
What special requirements do export product packaging have?
Export packaging typically needs product information and compliance labels in destination country language, and packaging materials must meet importing country environmental requirements (e.g., EU Packaging Waste Directive). Full white E-flute printing quality meets export standards.
Need a Similar Packaging Solution?
Provide product info and packaging needs for a custom solution