Country: Japan

Category: Transit

This packaging innovation addresses the instability of regular slotted corrugated cartons (RSCs), a common type of corrugated board box, during material handling. Many manufacturers switch to corrugated board boxes with shifted creases on the flaps to improve load stability. However, this alternative increases production complexity, reduces compressive strength, and requires higher-grade materials, resulting in significantly higher costs.
We developed the “Koro-Pita Carton” by thoroughly analyzing the causes of RSC instability. We found that the bulging where the outer flaps meet at the center and the lifting of contents by the inner flaps both contribute to rolling during material handling. By redesigning the flap structure, we achieved a flat exterior and a self-adjusting inner flap that lowers under the weight of the contents, thereby preventing movement and improving stability.
This enhanced stability is particularly effective when cartons are stacked on pallets and transported on conveyor belts or trucks—situations in which rolling or shifting can occur due to vibration or uneven surfaces.

Key features:
• Flat outer appearance: Achieved by optimizing the flap folding method.
• Self-stabilizing inner flap: Creases allow the flaps to bend downward under the weight of the contents, preventing internal shifting during material handling.

Benefits of Switching from a Corrugated Board Box with Shifted Creases on the Flaps (BA Flute) to a Koro-Pita Carton:
• Production efficiency: One process is eliminated, reducing lead time by one day.
• Cost reduction: Material optimization enabled a 7% cost savings.
• Strength Improvement: Compression strength increased by 45% compared to BA flute with the same material.

This solution allows for the use of standard corrugated cardboard boxes without compromising transport stability. It offers a cost-effective and sustainable alternative to conventional methods.