PackMojo

How to Pre-Fold Corrugated Boxes for Easier Assembly

Pre-folding corrugated boxes before assembling them is a crucial step that can save time, reduce frustration, and ensure a secure pack. By taking a few extra moments to pre-fold the box along its creases, you can significantly reduce the resistance of the cardboard and make the assembly process much smoother.

Why Pre-Folding Matters

Corrugated boxes are designed with creases that allow them to fold into shape. However, if these creases are not pre-folded, the cardboard can resist folding and attempt to return to its original flat state. This rebound effect can create tension, making it harder to assemble the box and causing flaps to spring back. Pre-folding ensures the cardboard "remembers" its folded position, making it easier to assemble and secure with adhesive.

Pre-folded Creases for Box Assembly

Step-by-Step Guide to Pre-Folding Boxes

1. Start with the front flap

  • Firmly fold the front flap downward along its crease.
  • Press down firmly to create a sharp, defined fold.
  • This step helps prevent the flap from rebounding or springing back, especially important for mailer boxes with an adhesive.

2. Pre-fold all creases

  • Fold each flap and side of the box along its designated crease.
  • Apply pressure to ensure the cardboard stays in the folded position.
  • This reduces resistance and makes the box easier to assemble.

3. Press and hold

  • After pre-folding, press down firmly on each crease for a few seconds.
  • This helps the cardboard "set" in its folded position, minimizing rebound.

4. Assemble the box

  • Once all creases are pre-folded, assemble the box as usual.
  • You’ll notice that the flaps stay in place more easily, and if you’re using a box with an adhesive, the adhesive will hold more securely.

Benefits of Pre-Folding

  • Reduces rebound: Pre-folding prevents flaps from springing back, ensuring a tighter seal.
  • Saves time: Pre-folded boxes are quicker to assemble, especially during high-volume packing.
  • Improves adhesion: With less tension on the flaps, adhesive or tape bonds more effectively.


Pro Tip: Use a Flat Surface
When pre-folding, work on a flat, sturdy surface. This allows you to apply even pressure and create clean, sharp folds.

By following these simple steps, your packing team can assemble corrugated boxes more efficiently and securely. Pre-folding is a small step that makes a big difference in the packing process!