Gap Flaps Yield Savings and Sustainability
Small RSC Design Change Yields Cost and Sustainability Benefits
A Regular Slotted Carton (RSC) is characterized by having the top and bottom outer flaps meet in the center of the box. Shortening the length of the outer flaps creates a gap where the flaps meet. This design modification, known as a gap flap, econo flap, or shy flap, is employed to reduce the cost of the container and the amount of corrugated used to manufacture it. Gaps are typically from 1/4″ wide to 3/4″, and sometimes greater depending on the application and size of the shipping box.
For large boxes purchased in high volume, the material reduction produced by the gap in the outer flaps adds up. This design approach is often used for the packaging of appliances, large metal fabricated parts, electronic equipment, remanufactured products and parts, pre-packaged process foods, and intra-plant shipments.
Obviously, creating a gap in the shipping container creates a greater potential for contamination. Consequently, the sealing method used to seal gap flap boxes should be considered carefully. Carton sealing tape, as opposed to hot melt glues, cold melt glues, and staples, completely covers the gap, preventing external matter from penetrating the case.
Water activated carton sealing tape (WAT), is most frequently purchased in 3″ width, adequate for covering most gaps. Pressure sensitive carton sealing tape, however, is normally used in 2″ width, which may create difficulties when applied manually. To ensure that gaps are consistently covered, we recommend automatic or semi automatic case sealing equipment for the sealing of a gap flap container.
Heritage Pioneer has an experienced corrugated design team to help you determine if the gap flap concept has potential in your application. If you’d like to discuss it, please give us a call. We can produce samples in our Phoenix facility and assist with test shipments and trial orders.
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Packaging Materials, Packaging Equipment, Packaging Solutions
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