At The Box Factory, we are committed to the continual improvement and development of our manufacturing facilities, ensuring we stay up to date with the latest technological breakthroughs to aid the production of our cardboard packaging, operational speed and overall efficiency.
Over the past ten years, we have invested £12 Million into our sites, acquiring some of the most sophisticated machinery in the industry. This considerable investment allows us to offer a short supply chain that facilitates a more personal and bespoke service, to the highest quality.
Despite our name, at The Box Factory, we manufacture more than just boxes. All our box designs can be customised, or alternatively, a box can be designed and manufactured specifically to meet your bespoke requirements.
Our Standard Range is as follows:
Offering a wide variety of uses across many industries, regular cases are amongst the most popular boxes we manufacture, thanks to their cost effective nature and versatility.
Offering endless possibilities and boasting extreme flexibility; die-cut boxes are a fantastic choice for products that require a precise fit due to unique shape or specialist features.
Multipurpose, often incorporating perforations or foldable flaps to create an enticing display, SRP is designed to end up on shop shelves, transforming from secure transit packaging to an on-shelf display in seconds.
Designed to be easily and quickly assembled by the end user, self-assembly packaging usually consists of interlocking flaps that create a sturdy and reliable box, removing the need for manufacturing seals or additional taping.
Ideal for product storage, shipment and display, trays are usually open top and are produced by folding and slotting the cardboard together.
For a more eco-conscious alternative to plastic packaging inserts, The Box Factory can produce bespoke and standard fitting for packaging products both securely and with enhanced presentation.
At The Box Factory, we use one of two processes to produce the physical structure of a box; cardboard sheets will be fed through either a die-cutting machine or a latitude case maker. Depending on the complexity of print and box design, this process can differ, however, both methods are capable of applying high-quality print, producing precisely measured cardboard blanks and can stitch or glue the boxes together if required.
For simpler boxes, which demand efficiency in lead time, both methods can create complete boxes in one pass. This can include the application of up to four printed colours, two on either side of the cardboard, as well as assembling and gluing or stitching where necessary. Boxes that require more complicated print, cutting, embossing or shaping will require multiple passes through either the casemaker or die cutter. Different steps will be performed separately to ensure unique specifications are completed to the highest quality.
For the most efficient storage and transportation, all packaging is supplied flat packed as standard.
Our manufacturing equipment is linked together via two fully automated pallet transfer lines, optimising the latest material handling technology. A highly sophisticated computer software system tracks all materials throughout the factories, incorporating real time reporting of job status and operator feedback.
In order to remain environmentally conscious and sustainable, we run a completely paperless operation. This also enables us to control and collect accurate and concise manufacturing and storage data.
Our large format, fast set, versatile machinery has revolutionised the way we produce corrugated packaging. A few key pieces of equipment in our factories include:
Latitude Casemakers: This entirely automated machinery has the capacity to produce up to 15,000 boxes per hour. Not only does it contain a rotary die cutter that can produce large quantities to accurate specification in quick succession but it has the ability to produce high quality print in one seamless process.
Latitude Casemakers improve overall operations within our factories; faster, more efficient production boosts output, allowing us to offer quicker lead times and more importantly consistency and accuracy is guaranteed.Weipong Rotary Large Format
Diecutter: For larger applications, our large format diecutter is the solution. Similar to the latitude casemaker, this diecutter can be used to cut, score and print cardboard to produce high quality boxes, alongside producing minimal waste offcuts. Automation also allows for faster lead times and more accuracy, even in the most intricate of designs.
VEGA Multipoint Gluer: For more intricate box designs, such as one with a crash lock base, more than one manufacturer seal or single glued area is required. Although this machine does not cut or score cardboard, it is fed blanks and will accurately fold them against their pre existing score lines. Multiple glue applicators apply hot glue to specific areas of the box, such a flaps or joints. The multipoint gluer is versatile, precise and customisable for your specific needs, making it ideal for maintaining the fast paced production in our factories, and ensuring the best service and lead times even on the most specialised packaging.
