Full Flap Auto Bottom Boxes for Wider Products

What is a full flap auto bottom box?

It is a tuck top carton with a different kind of floor. Instead of the pinwheel of a crash lock, the base is made from two long flaps that each reach halfway across. They meet along the centre line and cover the whole bottom.

Short flaps on the other two sides fold in underneath first. The long flaps then close over them, so you get two layers of board in the middle and no gaps at the corners.

Our single photo shows the shape well. One carton stands open with a green printed inside, while the other lies on its side with its flaps spread.

How is a full flap base different from a crash lock?

Both bases are glued before the cartons leave us, and both set up as you open the flat carton. The difference is the shape of the floor.

A crash lock folds four triangular sections that hook together in the middle. A full flap uses two wide rectangles that meet in a straight seam. On a long, wide carton, that straight seam gives a flatter, fuller floor.

If your carton is closer to a cube or an upright tube, the standard crash lock auto bottom box is usually the neater choice.

Who chooses a full flap bottom?

Brands with products that sit flat and wide. Think of jars lying side by side, a boxed kit or a two-piece gift set. Each needs a floor that is level all the way across.

It also suits cartons that get picked up and carried about, such as a gift box sold from a shop counter.

• Skincare and grooming sets of two or three items
• Tea and coffee gift sets
• Toy kits and craft sets
• Candles in wide tins
• Hotel welcome packs and amenity sets

What size full flap box do I need for a gift set?

Lay the items out exactly as they will sit in the carton. Measure the length and width of the whole group, then the height of the tallest item. Add about 3 mm to each footprint measurement and 5 mm to the height.

If the items are loose, plan a card insert at the same time. The insert takes up a little room, so its thickness goes into the size.

When in doubt, send us the items. The guide to measuring a tuck box and its clearance explains how clearance changes with an insert.

Can I print inside a full flap carton?

Yes. Our photo shows exactly that: a plain white outside with a green repeat pattern inside the lid and walls. Opening the lid reveals the colour, which makes an unboxing feel more considered.

Inside print is a second pass on the reverse of the board. It shows on the quote as a separate line, so you can compare with and without.

The base flaps are inside the carton too. Most people let the pattern run across them for a finished look.

Which board and finishes suit it?

350gsm white SBS is our standard board for this style. It gives a bright face for print and folds crisply. Kraft and other boards can be quoted on request.

Matt or soft touch lamination suit a gift set that will be handled. The long front panel has room for a foil name, a spot UV logo or embossed lettering.

The guide to white SBS and kraft board helps if you are torn between the two.

Can a full flap box have an insert or window?

Yes to both. A card insert with cut-outs holds two or three items apart so they do not knock together. It sits on the full flap floor, which gives it a level base.

A die-cut window on the front or lid shows the set inside, with or without clear film. Set it higher than the folded floor, so the base flaps are not on show through it.

How do I set up and pack a full flap carton?

Open the flat carton into a tube. As it squares up, the glued base flaps swing into place and meet. Press down on the floor from inside to settle them.

Place the insert, then the items. Fold in the lid dust flaps and push the tuck home. With a big batch of sets, open a row of cartons and drop the inserts in first. Loading the items is then a second, faster round.

For posting, put the carton inside a mailer. It is a retail box, and its corners will stay sharper with an outer layer around it.

What mistakes are common with full flap boxes?

Most of them come from planning the carton before the contents.

• Sizing the box before deciding on an insert
• Measuring a set of items in one row when they will sit in two
• Using a full flap on a small upright carton, where a crash lock is tidier
• Cutting a window so low that it shows the folded floor
• Leaving the inside unprinted when the lid opens in front of a customer

How do I order full flap auto bottom boxes?

You get a written price for your exact carton. Expect from £0.25 per unit; the board and run length move the figure. Send the item sizes, or the items themselves, and we work out the rest. When you are ready, request a full flap carton quote and follow these steps.

1. Lay out the set and send its overall size in mm.
2. Say whether you need an insert, a window or inside print.
3. Attach a logo or complete artwork for our designers to place, free.
4. Approve the proof showing the base flaps and every panel.
5. Your full flap cartons take 4–6 business days to make. Free tracked UK delivery follows in 2–3.