The Fold · From the factory floor
What are the different types of folding cartons?
The main types of folding cartons are the straight tuck end, reverse tuck end, auto-bottom, tuck top auto-bottom, 1-2-3 bottom, seal end, five-panel hanger and box-and-sleeve, and the right one depends on how heavy the product is, how it gets packed and where it will be sold.
The eight types, side by side
| Type | What it is | Best for |
|---|---|---|
| Straight tuck end | The everyday carton. Both end flaps tuck in from the same side. | Retail shelf products such as cosmetics, supplements and snacks. |
| Reverse tuck end | Like a straight tuck, but the top and bottom flaps tuck from opposite sides. | High volumes where the lowest cost matters. |
| Auto-bottom | A pre-glued bottom that snaps square the moment you pop it open. | Heavier products that need a strong, fast-to-assemble base. |
| Tuck top auto-bottom | An auto-lock bottom with a simple tuck-in top lid. | Fast hand-packing of heavier goods. |
| 1-2-3 bottom | A snap-lock bottom that assembles in three folds, with no glue needed. | Light-to-medium products and easy assembly. |
| Seal end | Both ends are glued shut by machine, for a sealed, tamper-evident pack. | High-speed lines, food and pharma. |
| Five-panel hanger | An extra panel with a hang hole for pegboard display. | Hardware, tools and accessories sold on a hook. |
| Box and sleeve | An inner box or tray with an open band that slides over it. | Wrapping trays, multipacks or premium inners. |
Straight tuck or reverse tuck?
This is the question people ask most, because the two look almost identical. On a straight tuck end the top and bottom flaps both open on the same side of the carton. On a reverse tuck end they open on opposite sides.
The reverse tuck is the workhorse for high volumes because the flat blanks nest tightly together on the press sheet, which wastes less board. The straight tuck is the more familiar shelf carton, which is why it is the one people usually mean when they say a folding carton.
How to choose
- Light product, simple pack: straight tuck end, or a 1-2-3 bottom if you want it to assemble without glue.
- Heavy product: an auto-bottom. The pre-glued base carries the weight better than a tucked one.
- Lowest cost at high volume: reverse tuck end.
- Filled on a high-speed line, or needs to show it has not been opened: seal end.
- Hangs on a peg: five-panel hanger.
- A premium reveal, or a multipack: box and sleeve.
Two display formats worth knowing
TWOFORM also designs two display formats built the same way: a display case pack, which ships a set of products and tears open into a shelf display, and a counter display, a tray with a pop-up header card that ships flat and locks together without glue.
Every type has the same size limits
Whichever style you choose, a folding carton works from 0.75 to 12 inches on every side. Below that the folds tear, and above it the board sags. The full reasoning is in the guide on the smallest size for a folding carton.
Frequently asked questions
What is the most common type of folding carton?
The straight tuck end. It is the everyday carton, with both end flaps tucking in from the same side.
What is the difference between a straight tuck and a reverse tuck?
On a straight tuck both flaps open on the same side. On a reverse tuck they open on opposite sides, which nests tighter on the press sheet and keeps cost down at high volumes.
Which folding carton is best for heavy products?
An auto-bottom or a tuck top auto-bottom. The pre-glued, snap-open base is built to carry weight.
Which carton assembles without glue?
The 1-2-3 bottom. It locks together in three folds.
Which carton is tamper-evident?
The seal end carton. Both ends are glued shut, so it shows if it has been opened.
Ready to try it? Design your own folding carton in TWOFORM. Related reading: the smallest size for a folding carton and folding cartons vs rigid boxes.