Custom Full Flap Auto Bottom
A standard auto bottom has flaps that meet in the middle, leaving a seam right where the weight sits. Extending those flaps so they overlap completely doubles the board across the whole base. Combined with a pre glued construction, it gives you the strongest folding base we make. We produce a lot of full flap auto bottom work at ZEE Packaging and heavy products are where it belongs.
Double Board Across The Base
A full flap auto bottom overlaps rather than meeting.
- The flaps extend the full width of the base
- That doubles the board across the entire bottom panel
- No seam sits where the weight presses down
- The glued construction spreads load evenly
- It snaps into shape when the carton is opened
- Assembly takes about a second per unit
Most operators choosing a full flap auto bottom have had a standard glued base give way under weight.
There is a clear threshold for stepping up.
- Glass bottles and jars, which concentrate load
- Liquids and anything with real density
- Multipacks and bundled products
- Cartons lifted repeatedly by the base
- Long transit routes with multiple handling points
- Unnecessary for light retail items on a shelf
- Full flap auto bottom with a tuck top the everyday build
- With a tongue lock top resisting accidental opening
- Window version showing the product through a die cut
- With a die cut insert holding contents steady
- Display lid version shipping sealed then opening for retail
- Corrugated format for heavier shipping applications
Sizes We Print Regular
Every full flap auto bottom carton is built to your product, though these run often:
- 3" x 3" x 6" for a bottle or jar
- 4" x 4" x 8" for a taller product
- 6" x 4" x 8" for a mid size item
- 8" x 6" x 10" for a larger product
- 5" x 3" x 7" for a boxed set
- 10" x 8" x 12" for bulk goods
Send us the filled weight, since the whole reason for this construction is the load it carries.
Board And Print
- SBS C1S at 20pt to 24pt for retail applications
- Corrugated for heavier shipping formats
- CCNB and duplex where a grey back is acceptable
- Kraft board for a natural or artisan position
- Matte, gloss and soft touch lamination
- Food grade certified stock where required
The glue seam is what we test properly. A weak bond under a doubled base still fails, so we sample with your actual product weight rather than assuming.
Materials Worth Choosing
- Recycled board grades, widely available here
- FSC certified stock, certificate available on request
- Soy based ink through the whole run
- Water based adhesive on the glued base
- More board used, though failures cost far more
- Right sizing so no board is wasted per carton
What Ordering Involves With Us
- 100 unit minimum, so a small brand can order properly
- Free 3D mockup and flat proof before anything prints
- Free dieline drawn by our own designer
- Physical sample on request to test the base under load
- Urgent turnaround at 5 to 8 business days
- Free shipping worldwide with nothing hidden
Frequently Asked Questions
How is it different to a standard auto bottom?
The flaps overlap fully rather than meeting in the middle. That doubles the board across the whole base panel.
How much is a full flap auto bottom box?
Rough estimate is $0.28 to $0.80 per unit plain, $0.45 to $1.20 with print and $0.70 to $1.80 with finishing at moderate quantity. Volume moves it. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
Does it use more board?
Yes, since the flaps extend further. The difference is small against what a failed base costs you.
How much weight will it hold?
Considerably more than a standard glued base. Send us the filled weight and we specify accordingly.
Does it still ship flat?
Yes, despite the pre gluing. It snaps into shape when opened, exactly like a standard auto bottom.
Is assembly any slower?
Not at all. It opens in about a second, the same as any glued base construction.
When is it overkill?
For light retail products. A standard auto bottom handles those perfectly well at lower cost.
