Stapler Cartridge Component Packaging Box Customization Case
Project Metrics
【Project Overview】
Industry: Healthcare
Product: Stapler cartridge components
Quantity: Initial small batch delivery | Type: Multiple series, various models
Material: Full white F-flute cardboard (2.0mm)
Process: Four-color printing + PANTONE spot color + lamination + die cutting
Delivery time: Batch delivery after sample confirmation
【Client Background】
A high-value medical device enterprise produces stapler cartridge components, with high product unit prices and strict requirements for packaging protection performance and brand image. Products are divided by series, each containing multiple specification models requiring differentiated packaging sizes.
💬 Customer Needs
The client had previously considered two packaging solutions: First, ordinary yellow-core corrugated paper boxes, which were low cost but had exposed yellow core affecting overall quality perception. Second, white cardboard boxes, which had good printing quality but insufficient impact resistance and could not meet transportation shockproof requirements. More challenging was that product sizes across multiple series varied significantly, requiring different packaging specifications while maintaining a unified brand visual style.
The client clearly required: no exposed yellow-core corrugation, balance between protection performance and appearance quality, and support for multi-specification product lines.
Core demands: Compression protection + Appearance quality + Multi-specification unified packaging standard.
Project challenges:
✓ Product is precision high-value device, requiring high transportation shockproofing
✓ Client explicitly required no exposed yellow-core corrugation
✓ Multiple product series need unified standards, but model sizes vary significantly
✓ Initial batch size limited, traditional large-batch model not suitable
💡 Solution
Lexiang used full white F-flute cardboard for the packaging boxes. Full white F-flute has white paper surface on both inner and outer sides, eliminating the problem of exposed yellow core, with a clean and high-end overall visual appearance. F-flute (Flute F) has fine corrugations, providing both compression resistance and cushioning performance. It also supports multiple processes including four-color printing, PANTONE spot color, lamination, and spot UV.
Selection analysis:
Why choose full white F-flute instead of yellow-core corrugated?
Traditional yellow-core corrugated exposes yellow core paper at box corners and inner surfaces. Even with exquisite surface printing, the exposed yellow corners give an inferior quality impression. Full white F-flute uses white core paper + white surface paper structure, showing white surfaces from any angle, with better printing color performance and significantly improved overall quality perception.
Why not use white cardboard boxes?
White cardboard boxes do have good printing quality, but white cardboard is solid paper with limited cushioning performance. When high-value staplers encounter drops or impacts during transportation, white cardboard boxes cannot effectively absorb impact force, resulting in high product damage risk. The wave structure of F-flute naturally provides cushioning capability.
Why not use E-flute or B-flute?
E-flute (1.5mm) is thinner, suitable for small electronic products, but provides insufficient cushioning for cartridge components with certain weight. B-flute (3mm) has stronger cushioning but thicker cardboard, with die cutting and gluing precision inferior to F-flute. F-flute (2.0mm) achieves a good balance between thickness, cushioning, and printing quality.
Why choose lamination?
Medical device packaging may come into contact with liquids or moisture during transportation and storage. Lamination (matte film) provides basic moisture protection while improving printing color saturation and wear resistance.
Production implementation and quality control:
① Sample confirmation (cardboard color, box type structure) → ② Full white F-flute cardboard customization
③ Four-color printing + PANTONE spot color printing → ④ Lamination (matte film 25μ)
⑤ Die cutting (precision die) → ⑥ Automatic box gluing (bottom-lock/double-insert/self-sealing)
⑦ Inspection (dimensions, creases, bonding strength) → ⑧ Packaging and shipping
Core quality control: F-flute cardboard burst strength and edge crush strength must meet medical device transportation packaging requirements. Die cutting precision remains consistent when switching between different model sizes.
✅ Project Results
【Project Results】
【Delivery Data】
✓ Delivered products: Stapler cartridge component F-flute color boxes (multiple series, various models)
✓ Material specifications: Full white F-flute cardboard (2.0mm)
✓ Process combination: Four-color printing + matte lamination (optional spot UV)
✓ Covered models: Unified packaging standard established by product line
【Usage Effects】
✓ Full white F-flute effectively improves overall packaging quality, no yellow core exposure
✓ Packaging is rigid and compression-resistant, good product protection during transportation
✓ Printing colors are bright and fine, brand LOGO and product information displayed clearly
✓ Batch production consistency meets long-term supply requirements
Case Summary:
High-value medical device packaging needs to balance protection performance and brand image. This case uses full white F-flute (2.0mm) to replace traditional yellow-core corrugated, eliminating the yellow core exposure problem at corners through white core paper, while retaining the compression and cushioning performance of corrugated structure. Combined with four-color printing and lamination processes, high-end brand display is achieved while ensuring transportation safety. For multi-specification product lines, visual consistency between different size packages is maintained through unified corrugated cardboard specifications and differentiated die cutting solutions.
Lexiang Experience:
Applicable scenarios: High-value medical devices, precision instrument transportation packaging, multi-SKU standard unification
Material recommendations: Choose E-flute (1.5mm) for light products (<0.5kg); choose F-flute (2.0mm) for medium-weight products (0.5-2kg); choose B-flute (3mm) for heavier products
Not applicable scenarios: Not suitable for premium gift box scenarios (corrugated surface printing quality not as good as white cardboard); not suitable for moisture-resistant/refrigerated environments
Notes: Full white F-flute costs about 20-30% more than ordinary yellow-core corrugated, but quality perception is significantly improved; high-value devices recommend adding inner tray to secure products
Professional Knowledge:
How to choose between full white F-flute vs ordinary yellow-core F-flute vs white cardboard box?
Full white F-flute: Both inner and outer surfaces are white, no yellow core exposure at corners, printing quality close to white cardboard but with corrugated cushioning. Suitable for medical devices, precision instruments, electronic products and other packaging requiring both protection and quality.
Yellow-core F-flute: Best cost-performance, standard choice for conventional transportation packaging. Suitable for scenarios insensitive to corner appearance.
White cardboard box: Best printing quality and stiffness, but no corrugated cushioning structure. Suitable for gift boxes, premium packaging, shelf display scenarios.
What does lamination do?
Matte film: Reduces reflection, improves printing quality perception, suitable for medical devices and high-end packaging.
Glossy film: Increases color saturation, shiny surface, suitable for e-commerce and food packaging.
Moisture protection: Laminated box surface resists slight moisture and fingerprints, improving durability.
Wear protection: Laminated printing surface less prone to scratches.
Why choose Lexiang:
✓ Mature experience in full white F-flute customization, no yellow core exposure issues
✓ Multi-specification product unified packaging standard, reducing client management costs
✓ Small batch minimum order, flexible for new product trials
✓ Packaging + inner tray integrated matching available
📸 📸 Results Gallery
❓ FAQ
What is the difference between full white F-flute and ordinary yellow-core F-flute?
Full white F-flute has white paper surface on both inner and outer sides, with no yellow core paper exposed at corners or inner surfaces, presenting a cleaner and more high-end overall visual appearance. Ordinary yellow-core F-flute is lower cost but inferior in display aesthetics compared to full white board.
What is the load-bearing capacity of F-flute?
F-flute (2.0mm) is suitable for medical device products weighing 0.5-2kg. Burst strength is approximately 800-1200kPa, edge crush strength approximately 4-6kN/m, which can pass ISTA transportation packaging tests. Specific values depend on cardboard material grade.
What is the minimum order quantity for stapler packaging boxes?
F-flute color boxes typically have a minimum order of 200-500 pieces, depending on size and process complexity. Bottom-lock/double-insert boxes are universal automatic gluing structures with relatively flexible minimum orders.
Can full white F-flute color boxes have hot stamping?
Yes. F-flute color boxes support hot stamping, spot UV, embossing and other surface processes. However, note that corrugated surface is not as smooth as white cardboard, so hot stamping precision is slightly compromised. Sample confirmation is recommended.
How to ensure batch consistency for multiple model packages?
Unified corrugated cardboard specifications (same weight, same materials), unified printing files and process parameters. Only die cutting dies change for different sizes, while printing design and brand colors remain unchanged.
How long is the sampling cycle for medical device packaging boxes?
F-flute color box samples are available in 2-3 days for structural samples. After confirming dimensions and box type, batch production can proceed. For printing effect confirmation, digital printing can be used first to check colors.
Can custom inner trays be made to secure products?
Yes. Supports corrugated inner lining, paper card inner tray, and grey board structure inner tray, customized with slots according to product contours to ensure products do not move inside the box.
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