A five panel folder, usually shortened to FPF, is a flat corrugated blank scored so that it folds around the product in five panels. The fifth panel laps back over the first, and the end flaps fold in on themselves, which leaves both ends double thick with no tape and no glue. It exists for products that a square carton handles badly: posters, framed art, blinds, signage, rulers, long flat kits.
Which dimension actually constrains the style
Depth. A five panel folder wants a shallow load. The wrap is cut from one piece, so every inch of depth is added four or five times over to the flat blank size, and past a certain point you are paying for board to make a shape an ordinary slotted carton makes more cheaply. If your product is close to cubic, the style is the wrong pick and a regular shipper will cost less. If it is long, flat and awkward, nothing else protects the ends as neatly.
Measuring for a wrap style
Lay the product flat, as it will ship, and take three numbers plus one judgement call.
- Length, edge to edge on the longest axis, including any frame, spine or protruding hardware.
- Width, across the piece at its widest.
- Depth, through the stack. If you ship more than one piece per box, measure the stack, not the piece, and measure it compressed the way it will actually sit.
- Clearance. A rigid framed item needs only a little, because the double thick ends do the protecting. A soft or fragile face may need a liner pad, which adds its own caliper to the depth.
What to state on the quote
| Field | What to give us |
|---|---|
| Internal dimensions | Length x width x depth, in that order, in inches or millimetres |
| Board | Single wall for light flat goods, double wall for weight or long transit |
| Load weight | Filled weight per box, which decides flute and liner |
| Closure | Tape, strapping, or a tuck and lock detail cut into the die |
| Plain kraft, one colour, or full coverage on the outer panel |
Board choice for long blanks
Long blanks flex. That is fine in a thin wall if the contents are rigid, and a problem if they are not. C flute is the usual general purpose choice at about 3/16 inch caliper. B flute at about 1/8 inch prints more cleanly and crushes less, which suits a printed retail wrap. Double wall is worth the money once the filled box is heavy enough that someone will pick it up by one end.
Minimum, price basis and lead time
The minimum is 100 units. Pricing runs from about $0.48 per unit at bulk volumes and is confirmed on your written quote. Three turnaround lanes are quoted per product: rush, which is expedited production plus air freight, standard on air, and cost saver on sea, starting from about 7 business days in production plus 2 to 5 days for delivery. The cutting die and the plates are included, along with design support, US shipping and a digital proof, so an internal size that matches your product exactly costs no more to tool than a near standard one.
If you are still deciding between a wrap and a conventional carton, the internal versus external logic on corrugated shipping box dimensions applies to both. When you have your three numbers, send them with a quote request and you will get back a dieline, a board recommendation and a written lead time.
