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What's a folding carton? It’s a box, most often made of paperboard. In general, if you can unfold it and knock it down flat, without destroying it, it's probably a folding carton. It’s likely made of paperboard from 12 pt. to 24 pt. Think about boxes for cornflakes. While they have been glued shut to keep them tamper evident at the store, once those glue spots are broken it easily knocks down flat. This is a general rule since some folding cartons are glued in their erected form at the point of filling. Folding cartons most often ship to the filling location knocked down flat. This gives them the advantage of being compact to ship and store. As a folding carton manufacturer, every few years we ship a carton flat, to the client, only to find out they expected it would be delivered completely assembled ready to drop in the product, it's an unhappy day for everyone involved. So that's an important point to cover up front if you or your company will also purchase the folding carton. Plastic folding carton is more firm and looks more beautiful, so it used more widely in packaging industry.

If it's not a folding carton, it might be a rigid box you are about to design. "Rigid" boxes are also called "turned edge", and "set-up" boxes or sometimes just called "set boxes". The base structure is generally made of a heavier chip board than a folding carton and is covered with a thinner material, like paper or fabric, called a label or "wrap". It ships completely set up, so you would need to destroy the box to knock it down flat. Think of high-end chocolates, iPhone and iPad boxes. Rigid boxes are often the way to go if the box you are designing is for a luxury product, and needs to give a high perceived value to the shopper. Some structures can be made with automation, some require hand wrapping. They can be bulky to ship and store. There is also a hybrid of a rigid box and a folding carton, called a "collapsible rigid box".

Corrugated boxes have a "fluted" material in the middle, and a flat liner top and bottom. If you have a really heavy product, this might be the way to go. If it needs to have high-end graphics on the outside of the corrugated, printing direct onto the corrugated is one option, but generally has limitations for really high-end treatments. Another option is printing on a thinner material and laminating it to the corrugated. This is often called a litho laminated box, or “litho lam”. A third option might be to put a sleeve made of something other than corrugated, like paperboard, around the corrugated box. Or use the corrugated as an insert to give strength to a folding carton.

Related reading: printed plastic packaging Clear Plastic Boxes