Packaging and Merchandising Design / Excercise 2 - Designing Custom Box for Non-Boxed Item

Week 3 - Week 5 (22/09/25 - 20/10/25)
Felice Jolin (0373636)
Packaging and Merchandising Design / Bachelor of Design (Hons) in Creative MediaExcercise 2 - Designing Custom Box for Non-Boxed Item

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TABLE OF CONTENT

Lectures

Instructions

Exercise

Feedback

Reflection 

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LECTURES

Week 4

Box Types & Styles 

Common Types of Boxes:

• Folding Cartons
• Rigid Boxes  
• Set-up Boxes   
• Cardboard Boxes   
• Corrugated Boxes   
• Paperboard Boxes 

1. Folding Cartons 

• Paperboard cartons/ paperboard boxes (Eg: Cereal box)

 

Fig 1.1 Folding Cartons (Week 4, 13/10/25)

 

2. Rigid Boxes 

• sturdier and do not fold or collapse as folding cartons do  
• Often, not always used for higher end products where perceived value is important  
• Used when the product within is heavy and in need of extra support. 

Fig 1.2 Rigid Box (Week 4, 13/10/25)

 

3. Corrugated Boxes 

• Also called corrugated board/corrugated fibreboard/combined board  
• Commonly refer as brown cardboard boxes  
• Typically has three layers  (A wavy or fluted layer sandwiched between two outer flat layers)

 

Fig 1.3 Corrugated Box (Week 4, 13/10/25)

Common Elements in  Folded Cartons  
Most common box styles are tuck top

 

There are 2 types of tuck top boxes:

• Reverse Tuck End (RTE) 
• Straight Tuck End (STE)  

[190gsm (light product) to 360gsm (heavy product)}

 

1. Reverse Tuck End (RTE) 

 

     Pros:

• Cost effective because 
• Easy assembly  
• Compact storing 
• Relatively quick to load the product in this packaging  
• Works well for lighter weight products 

 

    Cons:

• Not good for heavy products 
• Not as aesthetically pleasing because of the visible raw edges in the front of the box  

(Usually used for industries such as: health and beauty, cosmetics, pharmaceutical, electronics, and  nutraceutical) 

 

Fig 1.4 Reverse Tuck End (Week 4, 13/10/25)

 

 

2. Straight Tuck End (STE)  

    Pros:

• More luxurious 
• Avoids any blockade between the tuck flap and any front window film (see-through window to display the product)  
• Easy to assemble  
• Compact storing 
• Works well for lighter weight products  
• Relatively quick to load a product in this packaging 

    Cons:

• More expensive
• Manufacturers less boxes at one time per paperboard sheet  
• Not good for heavy products 

(Usually used for industries such as: health and beauty, and cosmetics)

Fig 1.5 Straight Tuck End (Week 4, 13/10/25)

 3. Tuck Top Snap-Lock Bottom (TTSLB) 

    Pros:

• Works well for heavier products 
• Relatively quick loading (the 3 steps are easy) 
• Compact storing (stores flat) for excess packaging inventory  
• Easy assembly  
• Sits well on retail shelves because package bottom is nice and flat 

    Cons: 

• More expensive than a bottom tuck box  
• Takes slightly more time to set-up 

(Usually used for industries such as: health and beauty, toys, food, pharmaceutical)

Fig 1.6 Tuck Top Snap Lock Bottom (Week 4, 13/10/25)

4. Tuck Top Auto Bottom (TTAB)

    Pros: 

• Works well for heavier products (bottom closure can handle more weight)  
• Very fast assembly  
• Super speedy loading  
• Compact storing 
• Sits well on retail shelves because package bottom is nice and flat

    Cons: 

• More expensive

(Usually used for industries such as: health and beauty, cosmetics, toys, food, pharmaceutical)

 

Fig 1.7 Tuck Top Auto Bottom (Week 4, 13/10/25)

Fig 1.8 Tuck Top Box Styles (Week 4, 13/10/25)

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INSTRUCTIONS

 

 Module Information Booklet

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EXERCISE

1. Item Slection

For week 3 in class, I selected a fragrance oil refill bottle, phone case and a notebook. Before bringing to class, I made sure this products do not have a box coming with it. Below are the items :

Fig 2.1 Non-box items (Week 3, 06/10/25)

After consultation with Mr.Shamsul, he suggested me to go with the  fragrance oil refill bottle and in addition with the fragrance oilif I have. Luckily, I have it all set, the frgrance oil, the refill bottle and the stick. I decided to go with it. 

Fig 2.2 Selected items (Week 3, 06/10/25)

2. Justification

The items I chosen doesn't come in a box. In addition, they were all sold separately, however, Muji didn't offer a bundle for it. An idea popped out of my mind to make a sort of like hampers box, consisting of the oil, stick and the refill bottle. That would enhance the appearance of the overall product, ease consumers bundling purchase and would attract consumers to purchase those 3 product at once.

In brief, it will enhance both presentation and functionality aspect as by bundling the fragrance oil, stick, and refill bottle together, it creates a cohesive and premium look which aligns with Muji’s minimalist brand identity. It gives a better organization and easy to store. By positioning it as a set, it would also be ideal to be a gift, eventually improving the product market and consumers' purchase experience. 

3. Sketches

Before starting, I look for references in pinterest for difusser box packaging. 

Fig 2.3 References (Week 3, 10/10/25)

Below I prepared 2 ideas of box. the first one is sliding box. So it's divided into 3 parts. The base, partition and cover. I include the partition inside so the items will not be jagged around. The cover has open part in top and bottom while just covers the side. 

 

Fig 2.4 Sketch #1 (Week 4, 13/10/25)

The second idea is folding box. The partition inside will be the same as the previous ones. The base and cover for this box is connected not like previous one.  

Fig 2.5 Sketch #2 (Week 4, 13/10/25)

Selected sketch is first one. Mr.Shamsul also suggested for the gap of refill bottle and glass bottle with stick to be far apart. As glass bottle and stick represent a thing, while the refill bottle represent the other thing. So it is to categorie and distinct the items. Below si the sketch of the dieline and partition ideas.

 

Fig 2.6 Sketch #1 details (Week 4, 13/10/25)

 4. Dimension and Measurements

Firstly, I tried to measure the size of the items choosen. 

Fig 2.7 Measuring (Week 4, 15/10/25)

 

 Secondly, I draw the dieline in Adobe Illustrator.

 

Fig 2.8 Dieline (Week 4, 15/10/25)

Thirdly, I draw manually on Model Card paper and cut it based on the dieline. 

Fig 2.9 Partition making process (Week 4, 15/10/25)

I started with the partition. The gap for the bottle is too big. I redo it and made compartment shape inside so it will not be loose.

Fig 2.10 New partition size (Week 4, 15/10/25)

 

 Moving on, I continue with the base. 

Fig 2.11 Base making process (Week 4, 15/10/25)

Last step, I made the cover.

 

Fig 2.12 Cover making process (Week 4, 15/10/25)

 

I also tried to do using laser cut in the printing room. Below is the process.

 

 

Fig 2.13 Lser cut process (Week 4, 15/10/25)

 

 

PROTOTYPE

 

Fig 2.14 Prototype by manual cut (Week 4, 15/10/25)

 

     

Fig 2.15 Prototype by laser cut  (Week 4, 17/10/25)

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FEEDBACK

Week 3
After consultation with Mr.Shamsul, he suggested me to go with the  fragrance oil refill bottle and in addition with the fragrance oil if I have. So it will be like a set package.

Week 4
This week, I showed my sketches. Mr.Shamsul select the first sketch and also suggested for the gap of refill bottle and glass bottle with stick to be far apart. As glass bottle and stick represent a thing, while the refill bottle represent the other thing. So it is to categories and distinct the items.

Week 5
Mr.Shamsul said actualy my packaging box it is good as it is made manually, but the cover and the box seems a little bit loose. He suggested me to do it one more time with laser cut. 

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REFLECTION 

Experience

I love doing art and craft. So doing this exercise is very exciting for me. Starting from the sketch to cutting process, I go through all with enjoyment. Although the deadline were quite tight, I am grateful I managed to finish in 2 weeks time. 

 

Observation

To make the folding part of the base box, i need to have a slight smaller edges, so when folded, the paper will not crack and folds tidily. As the refill bottle and glass bottle has the same height, I have seen confussion on how I would lay the stick together if the partition were the same height. I observed many designs online and decided to insert the stick like the way I did in the final product. I just need one partition and it holds tight the sticks.  

 

Finding 

Measurement of the items should be very careful and detail. Just like me, I repeated the partition cutting as the first one was too loose. So trial and error is needed here to make sure it packs the product safely.  

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