A microwave is heavy, boxy and has a glass door, which puts appliance packaging in a different category from retail cartons. The box is a structural component of the shipment, and the interior cushioning is what actually protects the product. To order, see microwave boxes.
Measure the appliance as it ships
- Door closed and latched, with any protective film already applied.
- Handle included, since a bar handle adds to the depth and is a point load on the carton wall.
- Feet fitted, since they set the height and they concentrate weight on the bottom cushion.
- Power cord coiled and secured where it will sit, which is usually a small compartment or a bag.
- Add the end cap or cushion thickness on every axis the cushions occupy, not a general allowance.
Cushioning carries the product, the box carries the stack
Two separate jobs, often confused. The end caps, whether moulded pulp, expanded foam or die cut corrugated, hold the appliance away from the walls and absorb drop energy. The carton carries the weight of everything stacked above it in a warehouse or a container. Specifying a heavier board will not fix poor cushioning, and better cushioning will not stop a stack from collapsing. Solve both.
Board grade follows load and stack height
Send the packed gross weight of one unit and the maximum number of cartons that will ever be stacked on top of each other. Those two numbers drive the board specification, and double wall is common in this category because of them. Flute profiles and what each one contributes are covered in our flute guide.
Pallet fit is a cost lever
| Carton footprint | Cartons per layer on a 48 x 40 in pallet |
|---|---|
| 24 x 20 in | 4 |
| 24 x 10 in | 8 |
| 16 x 20 in | 6 |
| 12 x 20 in | 8 |
These are external footprints that divide the deck exactly. A carton that overhangs the pallet edge loses a meaningful share of its stacking strength at the unsupported corner, which is precisely where a heavy appliance load concentrates.
Handling features
Hand holes make a heavy carton easier to lift, and they also remove board from exactly the panel that is carrying load. If you want them, place them where the cushioning supports the wall, and expect to compensate with board grade. Clear orientation arrows and a this-way-up marking matter more on appliance cartons than on almost anything else, because a microwave landed on its door is a write-off.
Ordering and turnaround
Minimum order is 100 boxes, from about $0.48 per unit at bulk volumes, confirmed on your written quote. The die, the plates, design support, US shipping and a digital proof before printing are included. We produce in West Chicago in the US and in Guangzhou in China. Turnaround is quoted per product in three lanes: rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days in production plus 2 to 5 days for delivery. For related heavy goods formats, see custom electronic boxes.
Send the appliance dimensions, the packed weight and your stack height, and we will propose a board grade, a cushion type and a pallet friendly footprint. Request a quote to start.
