A rigid corrugated box that uses ~26–28% less fiber than a standard RSC while staying automation‑friendly.
What it is
EdgeFold™ keeps only the two major flaps (front/back) on the top and bottom, deletes the two minor flaps, and adds narrow hemmed “dust lips” on the major flaps to close the side gaps. Everything else (rectangular footprint, glue tab, tape or auto‑lock closure) stays familiar—so it drops into current Amazon-style carton erectors and tape lines with minimal change.
Why it’s better (and still strong)
Biggest waste removed: On a regular slotted container (RSC), the four top and four bottom flaps account for a lot of board. The two minor flaps contribute little to compression strength but consume roughly half of total flap area. EdgeFold removes them.
Built‑in sealing: Each major flap includes a 15 mm hemmed dust lip that folds over the side edges when you close the box, creating a labyrinth seal (dust‑resistant without full minor flaps).
Edge stiffness where it matters: The hem creates a 3‑ply edge, boosting bending stiffness along the lid edges—where tape pulls and handling loads concentrate.
No new consumables: Close with a single strip of paper tape (or use the self‑locking option below). Labels, inline print, and scanning remain unchanged.
How much material you save (with real numbers)
For typical Amazon box sizes, the blank area reduction is consistently ~26–28%.
(Assumptions: two minor flaps removed on top and bottom; each major flap gets two 15 mm dust lips.)
Internal L × W × D (mm)
Standard RSC blank area (mm²)
EdgeFold blank area (mm²)
Saved (mm²)
Saved (%)
230 × 150 × 120
229,200
169,200
60,000
26.18%
330 × 230 × 180
505,200
367,200
138,000
27.32%
450 × 300 × 250
915,000
663,000
252,000
27.54%
Rule of thumb: with a 15 mm dust lip, expect ~26–28% less corrugate vs. an RSC of the same internal dimensions.
Construction details (ready for a dieline)
Blank: one piece with standard side glue tab.
Panels: four vertical panels (L, W, L, W).
Flaps:
Top & bottom: Only the two major flaps (on the L‑panels). Each major flap depth = W/2.
Dust lips: 15 mm hem along both short edges of each major flap. The lip creases 180° and tucks down inside when closed.
Optional tear‑open: 10–12 mm paper tear strip centered across the top major flaps.
Scores & cuts:
1 × vertical glue tab (25–35 mm).
Standard vertical scores at panel edges.
Top/bottom scores at D.
Kiss‑cut ladder scores every 10–15 mm around the body (“height‑reduction ladder,” see Variants).
Closure:
Baseline: 1 strip of 48–72 mm paper tape on top; 1 strip on bottom.
Auto‑lock option: “Ω‑Lock” tabs—mirror‑image omega cut‑outs centered in the two top major flaps interlock without tape (see Variants).
Material suggestions:
Small/medium: 23–32 ECT, B or E flute, high‑RC kraft liners.
Large/heavy: 32–44 ECT B/C dual or lightweight BC doublewall for parity with RSC BCT. (Pick exact grade after BCT/stack testing.)
How to erect and pack
Erect as usual; side glue tab forms the tube.
Close bottom: fold the two bottom major flaps; hemmed lips tuck in automatically; tape center seam.
Pack product; add dunnage if needed.
Close top: fold the two top major flaps; dust lips tuck in; apply paper tape (or engage Ω‑Lock).
Apply label and ship.
Automation: Existing flap‑plowing arms for minor flaps can be disabled or removed. Tape heads remain. Case erectors see nearly identical geometry—this is a low‑friction retrofit.
Variants (choose per SKU family)
EdgeFold‑Ω (No‑Tape Top) Interlocking “Ω‑Lock” tabs in the two top major flaps. Reduces tape use, speeds opening (still add a narrow tamper band if required).
EdgeFold‑Flex (Height‑Reduction Ladder) Perimeter ladder scores every 10–15 mm on the body. Cut down to product height, fold top flaps—zero void fill and more material saved from reduced box height, without new box SKUs.
EdgeFold‑Shield (Dust‑Sensitive SKUs) Add a 20–25 mm inner dust flange on the body side panels (minimal area) that mates with the flap lips for near‑continuous closure. Use for powders or tiny parts.
Performance & testing plan
Compression/BCT parity: Because minor flaps contribute little to Box Compression Test (BCT), expect near‑parity with the equivalent RSC at the same board grade. Validate with stack testing at target weight and dwell.
Transit robustness: Run ISTA parcel tests appropriate to your program (e.g., 3A/6‑Amazon SIOC where applicable): drop, vibration, compression, and temperature/humidity conditioning.
Operations check: Verify auto‑erector timing (flap plows off), tape head alignment, and scanner read rates on hem edges.
Where this wins
High‑throughput e‑commerce where void fill and labor are costly.
SKU families with similar W (so flap depth is stable) but variable heights (use Flex ladder).
Programs aiming to move away from plastic mailers without jumping to a full RSC.
What’s patentable here (claims to explore)
A corrugated shipper with two‑flap top/bottom plus integral hemmed dust lips that achieve dust control comparable to four‑flap designs.
The combination of hemmed edges + ladder height‑reduction that preserves BCT while removing two minor flaps.
A self‑locking interlock geometry (Ω‑Lock) optimized for two‑flap lids in corrugated.
Next steps I recommend
Pick two sizes (one small, one medium), cut sample blanks, and trial on an existing erector/taper.
Measure: fiber mass per blank, erect rate, tape usage, pack time, and BCT/stack.
Tune: dust lip width (start at 15 mm; 12–18 mm is the normal sweet spot), flap chamfers, and tear‑strip spec.
Pilot with 200–500 shipments across mixed carrier lanes; compare damage and CSAT to the current RSC.
Two quick alternate concepts (for different SKU types)
RibbonWrap™ Frame Box (extra‑lean): A single corrugated ribbon wraps the perimeter (forming the four vertical edges), and two very shallow “snap‑in” top/bottom panels span the faces. Massive area reduction; best for non‑dusty, bagged goods (apparel, boxed items).
Sleeve+Spines™: A kraft paper mailer with four folded micro‑flute corner spines glued inside for crush protection. Competes with plastic mailers while staying 100% paper.
If you want, I can turn EdgeFold™ into a parametric dieline (DXF/PDF) for any L × W × D so you can send it straight to a corrugator or a sample table.