Custom Tuck Bellow Flap Lock
A bellow flap folds in on itself like a concertina, which lets the closure expand or contract slightly rather than sitting at one fixed depth. Add a lock and it stays shut once it is closed. That combination handles products that vary a little in height. We produce a lot of tuck bellow flap lock work at ZEE Packaging and the flexibility is the point.
A Closure That Gives A Little
A tuck bellow flap lock adjusts to what is inside.
- The bellow fold expands or contracts as needed
- Slight variations in content height are absorbed
- A locking tab holds it closed once folded
- No glue or tape is used anywhere
- One carton covers products of similar but varying size
- The closure sits flat rather than bulging
Most brands choosing a tuck bellow flap lock have products that vary enough to make a fixed closure awkward.
Bellow Depth Against Lock Hold
Two features working together.
- The bellow must fold cleanly without creasing badly
- Board caliper affects how the concertina lies
- Too deep a bellow and the closure looks bulky
- The lock must engage across the full range of depths
- A shallow lock releases when the bellow is extended
- We sample the closure at both extremes of fill
- Standard tuck bellow flap lock the everyday build we run
- Deep bellow version for greater height variation
- With a tongue lock a firmer catch
- Window version showing product through a die cut
- With a die cut insert holding contents steady
- Food grade version for direct food contact
Sizes We Print Regular
Every tuck bellow flap lock carton is built to your product, though these run often:
- 3" x 2" x 5" for a standard retail item
- 4" x 3" x 6" for a larger product
- 2" x 2" x 4" for a small format
- 5" x 3" x 7" for a mid size item
- 6" x 4" x 8" for a bulkier product
- 8" x 6" x 2" for a flat format
Send us the range of heights you need covered, since the bellow depth follows from it.
Board And Print
- SBS C1S at 16pt to 22pt, since the bellow needs to fold easily
- 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
- Lighter caliper than a plain tuck would need
Heavy board fights a bellow fold. The concertina will not lie flat on stiff stock, so we usually specify lighter than clients expect.
Materials Worth Choosing
- Recycled board grades, widely available here
- FSC certified stock, certificate available on request
- Soy based ink through the whole run
- No adhesive at the closure
- One carton covering several product heights
- Right sizing so no board is wasted per unit
How Your Order Runs Here
- 100 unit minimum, so a small brand can test the format
- Free 3D mockup and flat proof before anything prints
- Free dieline drawn by our own designer
- Physical sample on request to test at both fill extremes
- Urgent turnaround at 5 to 8 business days
- Free shipping worldwide with nothing hidden
Frequently Asked Questions
How much height variation does it handle?
Half an inch or so comfortably. Beyond that the bellow bulges or the lock stops engaging.
Will the bellow crease badly?
Not on the right caliper. Heavy board resists the concertina and the fold looks untidy.
How much is a tuck bellow flap lock?
Rough estimate is $0.18 to $0.55 per unit plain, $0.30 to $0.80 with print and $0.48 to $1.25 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 the lock hold at every depth?
It should, which is why we sample at both the fullest and emptiest fill.
Is it slower to close?
Slightly, since the bellow has to fold correctly first. Staff learn it within a few cartons.
Can it hold food?
Yes, in food grade stock. It suits products where fill height varies naturally.
Why not just use two carton sizes?
You can, though one bellow carton covering both usually costs less overall in tooling and stock.
