eKomi   4.9/5.00
>2500 happy customers
Free delivery
100% customised
Customized print

Customized folding boxes: How to determine the right dimensions for your product and shipping packaging



Outer dimensions are important when it comes to storage, transport and stackability of your packaging - for example, when you deliver large quantities of your product stacked on pallets or send packages with a shipping service. If the packaging is too large, you waste valuable space - and that increases costs.

The rill dimension plays an important role for the manufacturers of corrugated cardboard packaging, but not for your configuration. Specifically, the rill dimension reflects the distance between the centers of the grooves where the cardboard is bent when it is erected. Its dimensions are therefore always between the inside and outside dimensions.

The inside dimension usually refers to the useful dimension of a folding box and therefore reflects how much space is available in the packaging. So it is decisive for whether a product fits into a package at all. Therefore, we ask you to always specify the inner dimension during configuration. This ensures that your custom folding box will have sufficient volume.
Illustration outside dimension and inside dimension
Faltschachtel Innenmaß


First of all, the inner dimensions of the packaging must be slightly larger than the corresponding product dimensions. There are several reasons for this: Firstly, the box volume must allow filling. Secondly, the product should be quick and easy to remove from the packaging. Thirdly, minor dimensional deviations can always occur during production, for example during gluing.

1. the basic rule: plan buffers

Regarding the configuration of custom folding boxes, we recommend adding a buffer of two to three millimeters to each product dimension (length, width and height). With this empty space, your packaging is large enough to ensure easy handling, even with small dimensional deviations. On the other hand, the packaging is not oversized, so that you offer your products optimal protection and use resources sparingly.
2. consider inlays and filling material
Inlays are used, for example, to protect sensitive goods from shocks or to position and anchor products with uneven shapes and weight distribution as securely as possible in the packaging. To ensure that the inlay has enough space and can provide the desired stability, you should also allow a buffer of two to three millimeters.

Similar to inlays, filling materials such as wood wool, wrapping paper, bubble cushions and polystyrene blocks serve to protect goods, especially in custom shipping boxes and folding boxes. How much additional cardboard volume this requires depends entirely on which filling material you choose.

Tip: We at packaging warehouse manufacture boxes from just one piece. This way, you can use individual sample boxes to test whether your dimensional ideas are practical.
Inlay Nahaufnahme
Sonderform Kissenschachtel
3. for special shapes: Note useful dimension
The inside dimensions do not match the useful dimensions of every package. This is the case for packaging with special shapes, for example for pillow boxes. Due to the inward curve on the closure flaps, the maximum fill height is around 25 millimeters less than the actual packaging height.

Also, it should be noted that the internal dimensions of the length and width of pillow boxes are only maximum values, because both the top and bottom of the packages are rounded.

The extent to which rounding affects the ideal dimensions of your packaging depends largely on the nature of your product and its individual dimensions. If you have any questions about this, please feel free to contact our team.


  • When configuring, you always specify the inside dimension.
  • Dimensions are always given according to the scheme length/width/height.
  • All dimensions must be given in millimeters.
  • The inner dimensions of the packaging should include at least two to three millimeters of buffer.
  • In addition to the product dimensions, inlays and filling materials must be considered when determining the inner dimensions.
  • For packaging with special shapes, the maximum filling height may differ from the packaging height.
Inlay für eine Faltschachtel
pack-on GmbH Bewertungen mit ekomi.de