Custom Full Overlap Corrugated Shipping Boxes
Also known as: FOL / Full Overlap Slotted Container / FEFCO 0203
Heavy‑duty flaps. Superior crush resistance. E‑commerce and freight ready.
What is a Full Overlap (FOL) Box?
A Full Overlap (FOL) box is a corrugated shipper where the outer flaps fully overlap across the top and/or bottom panels, rather than meeting in the middle like a standard carton. This creates double‑layer protection over the longest edges for better crush resistance, stacking strength, and edge protection—ideal for heavy, narrow, or high‑value products.
Specs at a Glance
| Key Spec | Available Options & Recommendations |
|---|---|
| Wall Construction | Single Wall (32-55 ECT), Double Wall (48-80+ ECT), Triple Wall (Heavy Freight) |
| Flute Profiles | C-Flute (Standard), B-Flute (Crush Resistance) |
| Strength Rating | ECT (Edge Crush Test) for stacking; Burst (Mullen) for containment/puncture |
| Closure Options | 2" or 3" Pressure Sensitive Tape, Water-Activated Tape (VAT), Heavy-Duty Staples, Strapping |
| Insert Integration | Corrugated Partitions, Foam End Caps, Molded Pulp Trays |
Comparison: FOL vs. Standard (RSC)
Buyers often compare Full Overlap (FOL) boxes with Regular Slotted Containers (RSC). Use comparison this to decide which fits your supply chain.
| Feature | Full Overlap (FOL) | Standard Box (RSC) |
|---|---|---|
| Flap Coverage | Full overlap (top & bottom or top only) | Meet at center (50% width) |
| Edge Protection | Double thickness at top/bottom edges | Single thickness |
| Stacking Strength | Superior (flaps act as reinforcement) | Standard |
| Material Usage | Higher (~20-40% more board) | Efficient (Standard) |
| Best For | Heavy, narrow, fragile, flat items | General purpose shipping |
How to Spec & Measure
Getting an accurate quote starts with the right specs. Measure based on the inner dimensions (L x W x D) to ensure your product fits.
- Dimensions:Always specify ID (Inner Dimensions) as Length x Width x Depth.
- Weight Load:Total weight of product inside. Determines board grade (ECT).
- Stack Height:How high will they adhere on a pallet? Critical for compression strength.
- Route-to-Market:Parcel (FedEx/UPS) vs. LTL Freight. Parcel requires higher burst/crush protection.
Built for Demanding Shipments
Overlapping flaps add rigidity where it matters most—reducing panel bowing and improving performance in parcel networks and LTL freight.
- Better End Protection: Double layers at edges guard against drops and conveyor impacts
- Secure Sealing: Wider tape surface for strong top/bottom closures
Best-Fit Use Cases
Heavy & Narrow Items
Machinery parts, tools, and dense hardware that would cause standard boxes to bow.
High-Value Goods
Electronics, medical devices, and kits requiring tamper-evidence and extra drop protection.
SIOC E-Commerce
"Ship in Own Container" items that bypass outer boxes. FOL provides the necessary ruggedness.
Flat Items
Mirrors, frames, or panels where edge crush protection is vital during transit.
Rough Freight
LTL shipments subject to stacking and mixed-pallet conditions.
What Impact Costs?
Understanding cost drivers helps you optimize your packaging budget without sacrificing performance.
- Board Grade: Heavier walls (Double/Triple) cost more but save on breakage.
- Box Dimensions: Larger overlapping flaps consume more square footage of board.
- Quantity: Scale drives down per-unit manufacturing costs significantly.
- Print Finishes: High-end litho labels add cost vs. direct flexo printing.
- Tooling: Custom cutting dies or print plates are one-time setup fees.