Custom Full Overlap Containers for Heavy, Long or Awkward Loads

What is a full overlap container?

A full overlap container starts as a flat slotted corrugated sheet. You fold it into a four-flap carton, but the top and bottom close in a different way from a standard box.

The two long outer flaps do not stop at the center. They reach all the way across and cover the shorter inner flaps.

The result is a full second layer of board on both ends. This style is known as FEFCO 0203, and you can browse related styles in our corrugated and shipping box range.

Who buys full overlap containers?

Hardware wholesalers, auto parts sellers and tile suppliers order them often. So do restaurants moving canned goods or glassware, and offices boxing up files for storage.

Etsy and Shopify sellers use them for pottery, stone pieces and cast iron. Long goods such as curtain rods and rolled fabric suit the style, because standard flaps on a slim box barely meet.

Warehouses like the flat, double layer top. The next carton sits level on it, so stacks stay straight. If you ship single orders to customers, our ecommerce shipping boxes may also fit.

Single wall or double wall for a full overlap container?

Most FOL orders carry weight, so BC flute double wall at about 1/4 in (7 mm) is the usual pick. The thick side walls resist crushing while the overlap guards the ends.

Lighter long goods can go in C flute single wall at about 5/32 in (4 mm). Slim items like trim rarely need more.

Not sure which to choose? Tell us your heaviest item and how high you stack. You can also compare double wall boxes for heavy loads.

Can I print on full overlap containers?

Yes. Warehouse teams often print size codes, handling arrows and a logo, so cartons are quick to find and sort.

Print runs plain, one color, two color or full color CMYK, inside and outside, on kraft or white board. The wide top flap is the best spot for a logo because it is the first face people see.

For extra polish, choose embossing, foil stamping, spot UV, or a matte or gloss laminate. Place your artwork in Design Your Box. We send a free design proof before anything is printed, and our designers help with layout at no charge.

Packing and sealing an FOL box

Fold the short inner flaps in first. Then close the two long flaps over them. Run tape along the exposed edge and carry it down each side panel.

For dense goods, add a strip across each end as well. Fill the box so contents sit snug under the flaps, because the double layer works best with support beneath it.

Wrap anything with sharp corners, or add a corrugated pad so it cannot punch through a side wall.

Mark the contents and weight on one end panel. Whoever lifts the box then knows what to expect.

How is an FOL different from a regular slotted container?

Only the flap depth changes. On a regular box the long flaps are half the width and meet in the middle. On an FOL they are the full width and overlap.

That single change makes the ends much tougher. If your cartons travel heavy or sit under a stack, the overlap is often worth it. Our regular slotted containers are the lighter alternative.

Both fold from flat the same way, so your packers learn nothing new when you switch.

Common mistakes when ordering full overlap containers

Do not choose an FOL for light, soft goods. The extra board adds cost without much benefit, and a standard box does the same job.

Watch very wide sizes. The flaps match the width, so a wide FOL uses a lot of board. For wide, shallow goods, a different style may fit better.

Also check the closed outside size against your shelving and carrier size limits. The added layers can matter. Our guide to the cheapest way to ship boxes covers those limits.