Custom Full Overlap Containers for Heavy and Awkward Loads

What is a full overlap container?

A full overlap container looks like a normal four-flap carton until you close it. Instead of meeting in the middle, the two long flaps each reach right across the box and lie one on top of the other.

That overlap puts two layers of board across the whole top and the whole base. Add the short inner flaps beneath and some areas carry three layers.

The FEFCO code for the style is 0203. It is one of the heavier-duty options in our shipping and corrugated box range.

Who orders full overlap containers?

FOL boxes suit trades that ship weight. Engineering firms use them for parts and fittings. Ceramic and tile sellers use them for flat but heavy stock. Removals firms like them for books and kitchenware.

They are also handy for long, slim goods. On a narrow box, normal flaps would barely meet. Full overlap flaps cover the end cleanly and give a firm surface to tape.

Some customers also use FOL boxes for goods that ship by pallet. The flat, double-layered top gives the next carton a firm surface to sit on, so the stack stays level.

Single wall or double wall for an FOL?

Because full overlap boxes usually carry weight, BC double wall at about 7 mm is the most common choice. It resists crushing on the sides while the overlap protects the ends.

For lighter long boxes, C flute single wall at about 4 mm can be enough. The double layer on the top and base already adds stiffness at each end.

If you are torn between the two, tell us the heaviest item you plan to pack and how high the cartons will be stacked. We will suggest a board on your quote.

Can full overlap containers be printed?

Yes. Many trade users print size codes, handling arrows and a logo, much like the dimension marks seen on warehouse cartons. That makes picking and checking faster.

We offer one colour, two colour or full colour CMYK on kraft or white board. The large top flap is a good place for a logo, since it is the first face anyone sees. Laminations, spot UV, foil and embossing are available when the box needs to look smart too.

Every print order comes with a free digital proof and free layout help from our designers.

How should I pack and seal an FOL box?

Fold the inner flaps first, then the two long flaps over them. Tape along the exposed edge of the top flap, and carry the tape down the side panel.

For heavy goods, add tape across each end as well. Fill the box so the goods sit right up under the flaps; the double layer works best when it has support beneath.

If the goods have sharp corners, wrap them or add a layer of corrugated padding so they cannot work through the side walls.

Write or print the contents and weight on one end panel. Anyone lifting the box then knows what to expect before they bend down to pick it up.

What should I avoid when ordering full overlap containers?

Do not pick an FOL just for light, soft goods. The extra board adds weight and cost without much gain, and an RSC will do the same job.

Watch very wide boxes. Because the flaps match the width, a very wide FOL has very large flaps, which use more board. For wide, shallow goods, a folding style may fit better.

Finally, check the closed outside size against any shelving or courier size band. The extra layers add a few millimetres that can matter. Our tips on keeping UK parcel costs down explain those bands.

How does an FOL differ from an RSC?

The only change is flap depth. On an RSC the long flaps are half the box width and meet in the centre. On an FOL they are the full width and overlap completely.

That one change makes the top and base much tougher. If your boxes travel heavy, get thrown around or stand under weight, the full overlap is usually worth it.

Both styles fold from flat in the same way, so your packing team will not need to learn anything new when you switch.