Everything ships flat and folds at the point of use, which takes freight and warehouse space out of the program.

What We Build

Crating and enclosures. Fiber crating for long or awkward parts getting damaged in transit. Ships flat, folds to a rigid corner, and closes by interlock or tape depending on the part. This is where wood crating gets replaced.

Layer and edge protection. Sheets, pads, and formed pieces that separate parts within a load and absorb contact.

Formed carriers. Structures that hold and separate individual units within a package.

K Score

The fold is the hard part. Kerf cutting weakens the board at the bend, and conventional scoring cracks or delaminates a coated or printed face. K Score is a rotary-formed groove that lets laminated board fold up to 180 degrees without either failure, so a poly-coated or printed structure ships flat and assembles clean.

K Score is also how caliper comes down. Thinner board is cheaper board, but it warps, and the score is what holds the geometry.

US Patent 12,479,198, granted November 2025.

Value Engineering

Cost comes out of a package in caliper, and caliper is limited by what the structure holds without warping.

On one box and liner program we took 10 to 12 percent out of the material cost by reducing caliper from 122-pt to 80-pt. Going thinner introduced warp, so we applied K Score to control it and took another 5 to 8 percent out at 68-pt. The package held its geometry at a caliper the customer had been told was not workable.

Design Process

Design is included with the program. Four people work on packaging design, led by our Director of Sales and New Product Development.

The work starts with the part and the failure mode. Structural design is done in CAD, the design is built for the actual handling and shipping conditions, and prototypes come off a digital cutting table in ten business days, so you have a real sample in hand rather than a drawing.

Our design group and test lab then run the sample through conditioning and physical testing before the first production order.

Capability

Materials

Virgin kraft, recycled board, or a combination. Polyethylene coating is extruded in house. Foil, silicone, and film liners are available. Construction is built to the part rather than to a roll we already own.