A carton sample can look right on a desk and become awkward once someone packs the product. The lid may need force to close. An accessory may have no assigned position. A dispatch label may cover the information the customer needs to see.
Sample approval is the chance to find these problems while changes are still being discussed. Give the sample to the people who will use it and assess the complete packing arrangement.
What should I record before reviewing a carton sample?
Before the review, record the sample reference, drawing revision, dimensions and measurement basis. Include the proposed board specification and artwork version where relevant.
Ask what the sample represents. Is it a plain structural sample, a printed sample or a sample made with the intended production materials? Different sample types answer different questions. A plain sample cannot confirm the appearance of the final print.
If the supplier uses a FEFCO design code, record it alongside the drawing. The FEFCO code provides a common way to identify box designs. The code does not replace the dimensions, material specification or job-specific details.
How do I check whether my product fits the sample?
Use the intended product rather than estimating fit from an empty carton. Add its bag, wrap, inserts, dividers, accessories and paperwork.
Check that the product can enter and leave the pack without forcing it against an edge or pulling on a fragile component. Confirm that the arrangement is repeatable. If two packers load the same order differently, the instruction needs more detail.
Look at the remaining space. Decide where separation, restraint or cushioning is needed for the product and handling route. DHL's packing guidance treats the inner packing materials and separation between multiple items as part of the complete package.
If the sample cannot be checked with the actual product, record the limitation. Do not quietly turn an estimated fit into an approved fit.
How do I check the sample works in the packing process?
Ask a packer to assemble, fill, close and label the sample using the intended process. Observe the work before explaining how you expected it to happen.
Check whether the folds are clear, the flaps close as intended and the chosen tape or other closure can be applied properly. If the carton must run through packing equipment, include the relevant operators and the agreed machine trial. Hand assembly cannot confirm how a carton will behave on that equipment.
Count the extra steps. A loose divider that is difficult to position or a flap that needs constant adjustment deserves a note, even if the pack eventually closes. These observations can guide a revision without inventing a time-saving claim.
How should I check the artwork on a carton sample?
On the assembled carton, in the positions people will actually see it.
A flat artwork proof and an assembled carton show different views of the same design. Read the product name, code, quantity and handling information in the positions people will actually see.
Check that folds, seams, tape and dispatch labels do not hide important information. Confirm the approved text and artwork revision. Test any barcode or QR code with the intended scanning setup rather than approving it by appearance alone.
For printing-specific questions, use Exxo's guide to carton artwork and proofs. Keep the structural and artwork decisions clearly identified in the approval record.
Does an approved sample prove the carton will survive transport?
No.
A satisfactory fit and a clean print are useful findings. They do not establish how the complete pack will perform during stacking, drops, vibration or a particular delivery route.
Discuss the handling conditions and decide what further checks or tests are needed. FEFCO lists separate methods for compression, drop and vibration testing of corrugated packaging. Selecting a suitable evaluation depends on the actual pack and distribution conditions.
Do not print a stacking limit or make a load claim simply because a sample feels strong.
What should a sample approval record include?
Use a record that the buyer, supplier and packing team can all identify later:
- Sample reference and specification revision.
- Product and accessory combination checked.
- Board, dimensions and agreed measurement basis.
- Artwork version and closure method.
- Observations, requested changes and unresolved items.
- Further trials or tests required.
- Approval date and the person responsible for the decision.
Separate an accepted feature from a requested change. If the dimensions change, identify the revised sample and drawing before anyone treats the earlier sign-off as current.
What should I tell Exxo when requesting a custom carton sample?
When discussing custom cartons with Exxo, explain the product, protective materials, closure and packing process you plan to use. Ask what the proposed sample will cover and which points still need checking.
Send your product details and sample questions through the contact section. A clear approval record gives the next discussion a specific starting point.