Carton Box Guide · Process

Carton Box Process: Joining & Printing Methods

Once a box is cut and formed, two more decisions shape its strength and look: how the sides are held together, and how the surface is printed.

Joining: Wire Stitching or Glue

The sides of a box are held together in one of two ways. Wire stitching punches through and locks the flaps with metal wire — the strongest option for large boxes, heavy loads, and double wall. Glue gives a smooth surface with no protruding wire — neater for boxes that are printed all over. The choice depends on the weight, the type of part, and whether the box needs to look clean.

Detail of a wire-stitched joint on a JMP carton box. Metal wire holds the sides of the box together. — Wire stitching on a box joint — the choice for large boxes and heavy loads.

Printing Methods: Screen, Flexo, Digital

Three printing methods are common for corrugated board, each with a different character. None is "the best" — the right one depends on volume, design complexity, material type, and budget.

Screen printing

A traditional technique that uses a porous mesh (the screen) as the medium for transferring ink. A stencil is made on the screen, then ink is pushed through the open areas of the stencil with a squeegee — forming the design directly on the carton surface.

Strengths

Thick, solid colour
Flexible for complex designs
Economical at small to medium quantities

Weaknesses

Slower than the other methods
Labour-intensive, less efficient for mass production
Results can vary with the operator's skill

Flexography (flexo)

Uses a flexible plate made of rubber or photopolymer with a raised design. The plate transfers ink through a series of rollers, allowing fast printing on a range of materials, including corrugated board. At JMP, flexo runs up to 4 colours with a ceramic anilox + doctor blade.

Strengths

High speed, ideal for mass production
Low cost per unit at high volume
The choice for repeat orders such as automotive parts

Weaknesses

High upfront cost from plate making
Less sharp for very fine detail
Less economical at small quantities (significant setup)

Digital printing

A modern method that transfers a digital design straight to the carton surface with no printing plate. Design changes are fast and flexible — a good fit for small to medium runs with a lot of design variation.

Strengths