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You can’t choose the right box unless you know what’s “under the good” of popular packaging choices. The choice often comes down to a die-cut box versus a regular slotted container (RSC) box. While both can be effective, decision-makers still need to know the key differences when making the final call. Which style of corrugated box is the best? Take a look at the fast facts on choosing between die-cut boxes and RSC boxes.

First Things First: Why Cardboard Is Such an Excellent Choice

Both die-cut boxes and RSCs share the quality of being made of cardboard. It’s not an accident that cardboard is the preferred packaging choice of many brands. Here’s a look at why cardboard endures:

• It’s durable against rips, tears and crushing.
• It holds its structure nicely.
• It can be layered for custom support.
• It’s easy to source.
• It can be used to make boxes of all sizes.
• Most cardboard products have eco-friendly characteristics. Cardboard packaging is often recyclable.

Cardboard is extremely customizable. While the structure provided by cardboard is often enough to safely house many products, there is much more brands can do to increase cardboard’s durability. In fact, cardboard is one of the most receptive materials when it comes to coatings and protective layers.

Covering the Basics of Die-Cut Boxes

The first option to consider after deciding that cardboard is the way is the die-cut box. While die-cut boxes are familiar to all, understanding the process of how die-cut boxes are made helps to highlight their benefits. Die-cut boxes are called die-cut boxes because they are created using a machine that’s known as a die cutter. A die-cutter machine slices sheets of corrugated cardboard into boxes. This press-style production is what gives die-cut boxes their incredible versatility. Boxes can be created in a large selection of shapes and sizes simply by adjusting the specifications of the machine. Ultimately, this means that die-cut boxes can be cut into nearly any size for your product.

Once they are cut, the walls that form the structure of a die-cut box are locked into place to create its shape. Next, the lid can be folded into place. The way that die-cut boxes are built as a “whole” creates a big advantage for giving these boxes immense levels of structural integrity. In fact, it’s this incredible strength that makes die-cut boxes so desirable when packaging, storing, and shipping bulkier items that might put stress on shipping materials. In addition, the double padding that’s built into the walls of die-cut boxes creates a built-in buffer without the need to spend extra on padding.

When should brands consider die-cut boxes? Die-cut boxes enjoy universal application from brands in all industries and genres. However, they are considered the standard among shippers tasked with shipping large, bulky, or fragile items internationally because they are extremely resilient in situations that require a large amount of handling.

Die-cut boxes are also exceptional when brands need to add logos, text, or instructions to packaging. Adding these elements to die-cut boxes is generally very simple to do without a large cost investment. The ability to add text or graphics directly to packaging without the need to invest in the materials and time necessary to add after-market elements can save brands money.

There’s also one more big benefit to die-cut boxes in the category of customer experience that brands should know about! As most brand managers know, the unboxing experience is quickly becoming a key point in the customer experience. Research clearly shows that the appearance of packaging causes consumers to make “snap judgments” of products. These subconscious first impressions can be nearly impossible to shake off.

How do die-cut boxes help to improve first impressions? While the determining factor is subtle, it’s actually very important. Die-cut boxes are graceful because they are designed “as a whole” when it comes to all of the parts fitting together. As a result, die-cut boxes require far less tape to stay secure than other boxes. This means that your customers won’t have to struggle to remove the firmly entrenched tape from the exterior of the box when trying to access your product.

Covering the Basics of RSC

Yes, it can be hard for any option to follow a talk on die-cut boxes. Die-cut boxes are a deeply entrenched favorite for many reasons. However, RSC boxes definitely hold their own in certain circumstances. Here’s the rundown on RSC boxes:

• They consist of four slats that meet for closure.
• They can be taped for better security.
• They can be used to ship a wide variety of different products.
• They can be ordered in many different sizes.

Many brands that do high shipping volumes appreciate how easy RSC boxes are to fold. However, the “quickness” of assembling these boxes is sometimes diminished by the fact that more tape is often needed to achieve a truly secure fit. In fact, tape is sometimes necessary to maintain the structural integrity of some RSC boxes during handling and shipping.

In addition to offering quick assembly, RSC boxes are easy to break down when compared to other shipping boxes. When you combine the fact that they’re easy to break down with the fact that they are almost always made from recycled materials, brands can see that there’s a big opportunity to make a sustainability statement using RSC boxes. This is important because customers are increasingly placing a higher and higher value on goods and packaging materials that are good for the environment.

However, there is one detail that causes RSC to lose some points in the efficiency category. RSC boxes often create empty space between the product and the sides of the packaging. As a result, most brands that utilize RSC boxes do end up adding some filler to smooth things out. The good news is that there are many eco-friendly options for filler made from things like recycled shredded paper.

Deciding Between Die-Cut Boxes and RSC Boxes: Which One Is Better?

Like most packaging choices, brands aren’t necessarily looking for the better option when deciding between die-cut boxes and RSC boxes. That’s because “better” doesn’t exist in a genre where packaging is chosen based on how it serves the needs of specific products. Here’s a look at the four categories to consider when deciding between die-cut and RSC for an upcoming product launch:

• Budget: Start with budget to make sure you’re making decisions based on what’s realistic. In general, die-cut boxes are more expensive to produce than RSC boxes. Paying for extra durability is often acceptable for brands that aren’t interested in losing costs down the road due to damaged and returned products. However, it’s important to know that RSC boxes are usually cheaper.
• Preferences Based on Past Experiences: Has your brand used one of these options in the past? Consider your experience when deciding if you want to continue with the same option. Bring in your team to audit what worked, what didn’t work and any updated needs that should be considered.
• The Specifics of Your Products and Shipping Methods: Does your company tend to ship multiple items at once? RSC boxes are actually popular for multi-item shipping because of their flexibility. The fact that you’ll need to add filler to buffer products in multi-item shipping experience erases some of the benefit of the built-in buffer of die-cut boxes that only applies when shipping one item at a time. However, die-cut boxes are still preferred in situations where delicate single-item shipments are being made.
• Customer Expectations: What does the market research say about your customers? Is your product something that tends to attract people looking for unboxing experiences they can share on social media? If the intention is to create an ultra-smooth unboxing, die-cut boxes work best. However, RSC is great for generating customer loyalty if your customers value eco-friendly values.

It’s important to understand the impact that both die-cut boxes and RSC boxes can have on product integrity and value perception based on your specs. That’s why making the right choice starts with a conversation with packaging experts. Book a consultation with Mid-Atlantic packaging to get a custom packaging quote covering all of the possibilities!