In the packaging industry, the choice between a Wrap Around (WA) and a Regular Slotted Container (RSC) is dictated by a meticulous analysis of operating costs, logistics, and product requirements.
This technical guide, created by the engineers at Duetti Packaging, aims to compare these two secondary packaging solutions based on crucial parameters such as robustness, warehouse footprint, and environmental impact.
1. The wrap around (WA) container #
The wrap around is a secondary package made from a flat corrugated blank, which is formed and sealed around the product.
Sealing occurs through the application of hot melt adhesive.
The WA is produced via the die-cutting process, which involves precise compression cutting between the die and the counter-die. In the subsequent phase, specialized tools proceed to remove the waste material.
Duetti Packaging Machinery suitable for WA:
- Monoblock Form-Fill-Seal DUETTI: WRAP 10, WRAP 12, WRAP 18.
- The WA machine also allows for the creation of trays.
2. Regular slotted containers (RSC) #
Regular slotted containers are the classic cardboard boxes, widely used in the packaging of industrial products.
Sealing occurs through the application of hot melt adhesive or adhesive tape.
A single box is created using a single flat sheet of corrugated cardboard, which, after being scored horizontally and then vertically, is folded and subsequently glued using the internal manufacturer’s joint.
RSCs are generally used for the purpose of transporting goods to the destination point.
Duetti Packaging Machinery suitable for RSC:
- For forming: FORMER 20 (glue or tape version), FORMER 30 (glue version), FORMER 50 (glue version).
- Form-Fill-Seal in a single solution (top loading monoblock): MULTIPACKER 5, MULTIPACKER 10, MULTIPACKER 20 (glue or tape version).
- For product insertion (top loading case packer): PACKER 10, PACKER 20, FLEX-ROBOT.
- For sealing the carton: CHN (tape closure), CHM (glue closure).
3. Technical comparison: 8 key points #
For an objective assessment, we have grouped 8 comparison points, highlighting the winner for each parameter.
| Parameter | Wrap Around (WA) | Regular Slotted Container (RSC) | Advantage |
| Cartons cost | Generally less expensive | Generally more expensive | WA |
| Robustness and thickness | Greater robustness, with lower thickness. Higher compression resistance | Lower robustness | WA |
| Storage | Smaller footprint (greater autonomy in machine magazine) | Larger footprint | WA |
| Machinery cost | Higher (more complex) | Lower (simpler) | RSC |
| Management/Maintenance | Higher complexity, longer size changeover times | Less complex, simpler operation | RSC |
| Filling flexibility | Cannot be manually filled | Can be manually filled in case of breakdown | RSC |
| Sealing methods | Hot melt glue or interlocking | Adhesive tape or hot melt glue | RSC |
| Display finish | Better finish, ideal for large-scale retail and display | Less attractive once opened | WA |
4. Detailed analysis of operational advantages #
A deeper analysis of the parameters shows how the choice directly influences costs and production logistics.
Costs, thickness, and logistics (WA advantageous) #
- Cost and robustness: the wrap around box is generally less expensive than the regular slotted container. This is due to its greater robustness and compression resistance, which allows for the use of a lower thickness cardboard.
- Storage and logistics: being of lower thickness, WA cardboard offers significant logistical advantages and allows for:
- Smaller footprint in storage and transport.
- Greater autonomy of the blank magazine (up to double the time without replenishment).
- Sustainability: the lower thickness of the WA translates into less material consumption. This offers direct environmental benefits, aligning with the stringent sustainability regulations required, for example, by large-scale retail (GDO/LSR).
Operability and line flexibility (RSC advantageous) #
- Cost and complexity of machinery: WA machines are generally more expensive and more complicated to manage. They require longer size changeover times, greater maintenance, and more skilled operators. RSC carton machines, conversely, are generally less costly and simpler.
- Filling flexibility: in case of machine failure, RSC cartons can be manually filled to prevent stopping production. WA cartons, due to their forming process, do not allow this manual operation.
- Sealing method: the RSC offers two sealing methods (adhesive tape or hot melt glue), while the WA allows sealing with hot melt glue or the interlocking system. The interlocking system, however, has many limitations as the box has weak resistance to compression compared to a glue-sealed box. The interlocking box also requires very precise blanks; this precision affects manufacturing costs.
Marketing and display functionality #
The WA is generally the industry’s choice of reference for creating displays to be placed directly on the shelf.
Choosing the ideal solution #
Choose the wrap around (WA) if your priorities are:
- Direct product exposure on the package at the point of sale.
- Logistics optimization and long-term savings.
Choose the regular slotted container (RSC) if your priorities are:
- Simple transport.
- Maximum operational flexibility (lower machine complexity and possibility of manual filling in case of breakdown).
Duetti Packaging is available to assist you in choosing the most suitable packaging for your product. Our technical support starts with the carton solution and extends to the optimal configuration of the packaging line.
Contact us for a personalized technical consultation.
