The customer's original half slotted container and stitched cap had proved the correct size, but the caps were seldom returned and tape damage seriously reduced its lifecycle. DS Smith Tri-Wall's replacement utilises a novel "jig-saw" outer base flap system to simplify both make-up and breakdown for flat packed returns and avoid taping.
The inner flaps were increased to meet, giving a flat surface for filling, while a "saloon-style" door was introduced in a main panel with a three-quarter length vertical slit, parallel vertical creasing and a cross panel slit at the bottom of the doors.
This allowed the two panels to be easily turned back to fold flat against the container where they are held in place by locking tabs. The vertical slit extends past the door panels so that an 'H' section plastic extrusion slides in place and maintains pack integrity in storage and transit.
The main container material is MoD quality double "A" flute corrugated for increased stacking strength. For the pack to be reusable the cap, formed from a "BA" flute combination, was redesigned to be self-locking.
