Posted on July 16, 2019 by Dennis Salazar

What are the flaps for on an e-commerce RSC style box?

Do you know why flaps matter?

We are very well known for the millions of die cut mailers we make for DTC shipping. However, what many people don’t know is that we also sell millions of paper and paperboard mailer envelopes. In addition, we also make truckloads of custom size and custom printed RSC shipping boxes for e-commerce applications.

The fact is that RSC style shipping boxes have some distinct advantages including lower cost per box, lower print plate costs and unless the RSC must be die cut for any reason, there are usually no cutting dies required.

RSC construction

Unlike die cut mailers that open like a cigar box with an attached lid at the back, RSC boxes have four flaps on top and bottom and are usually sealed with adhesive or more likely, two strips of tape. This is your standard shipping box or sometimes called a moving box.

The two flaps on the longer side are called the major flaps and the two on the shorter side, usually on the width are called the minor flap. Unless the box is square (12” X 12” for example) the majors meet in the middle and the minors are shorter, so they do not meet in the middle creating a gap between them on the inside of the box.

normal RSC Flaps create gap between minorsAvailable variations include “all flaps meet” and/or “FOL” (full overlap) of either minor or major flaps.

Aren’t flaps just redundant, unnecessary packaging?

Contrary to what some people believe, RSC flaps and variations of them provide many benefits including:

  • They protect the product being shipped with additional cushioning and strength. Especially with FOL or all flaps meet construction, you create a double wall box on top and bottom giving the box superior corner protection.
  • They can eliminate the need for additional top and/or bottom reinforcing support pads.
  • Extending the minor flaps eliminates the gap in between which means products like vertical bottles will stand upright and even.
  • We often recommend FOL boxes especially for larger, wholesale or retail or orders. Since most people open an RSC with a knife by cutting between the major panels, items like soft goods and apparel are especially vulnerable to accidental cutting. Some people add corrugated board pads to provide this protection but, usually extending the major flaps can do the same job at a lower cost.

We don’t sell boxes; we sell packaging solutions.

The point is don’t mistake the RSC boxes we make for our customers as the same boxes you pick-up at the office supply place or order from stock on the internet. What we offer is custom RSC box designs that are effective and will reduce your overall costs.

minor flaps meet for smooth bottomOur boxes are not two clicks away, we want to know what you are shipping, how you are shipping it and other details about your specific requirements. Every amazingly low-cost box we sell is made especially for our customers.  In fact, we have NO stock RSC boxes to offer, not even unprinted ones on our online green packaging store .

If you have a simple, basic application and you want unprinted RSC boxes, there are probably thousands of places where you can buy them. However, if you want a box that is custom printed beautifully and is engineered to satisfy YOUR needs, call us at 630-551-1700 or contact us at Salazar Packaging. Our experienced branded packaging advisors are eager to provide you with a no cost, no obligation consultation.

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