Why box style is just as important as box size when shipping cricket bats, hockey sticks, umbrellas and other long products

Shipping long items presents a unique challenge.

Unlike square or compact products, long items such as cricket bats, hockey sticks, umbrellas, curtain poles and engineering components place very different stresses on a cardboard box during transport.

A box that's perfectly suitable for a small parcel may flex, bend or even fail when used for a long product.

That's why choosing the correct packaging isn't simply about selecting the right dimensions. The style of box and the strength of the corrugated board are equally important.

In this guide, we'll explain why long products need specialist packaging, when to choose a 0201 ALT instead of a standard 0201, and why double wall corrugated board is often the best choice for longer boxes.

Why Long Boxes Behave Differently

Long cardboard boxes experience much greater bending forces than shorter cartons.

Throughout the delivery journey, parcels are:

• Stacked in cages.
• Loaded into vans.
• Carried by one end.
• Placed on conveyor systems.
• Stacked beneath heavier parcels.

Even if the contents aren't particularly heavy, the length of the parcel increases the amount the box can flex.

The longer the box, the more important the packaging design becomes.

Products That Benefit from Long Boxes

Long cardboard boxes are commonly used for:

• Cricket bats
• Hockey sticks
• Umbrellas
• Golf clubs
• Fishing rods
• Walking sticks
• Curtain poles
• Aluminium profiles
• Timber mouldings
• Signage
• Engineering components

Many of these products are relatively lightweight but still require strong packaging because of their length.

Choosing the Correct Box Size

Always choose a box that's as close as possible to the size of your product.

A box that's too large creates unnecessary movement, requiring additional packing materials and increasing the chance of damage.

A made-to-measure box provides a much better fit while reducing wasted space.

You can learn more in our guide:

Made-to-Measure Cardboard Boxes vs Standard Box Sizes

Why Box Style Matters

When shipping long products, many businesses focus entirely on the board grade.

In reality, the box style can have just as much influence on strength.

The two most common styles are:

• FEFCO 0201
• FEFCO 0201 ALT

Although they look almost identical, the way they're manufactured is very different.

What Is a Standard 0201?

A standard FEFCO 0201 is the most widely used shipping carton in the world.

It features:

• Four top flaps.
• Four bottom flaps.
• A manufacturer's joint running down one of the short ends of the box.

For most products, it's an excellent all-round packaging solution.

However, when the box becomes particularly long, there is a stronger alternative.

What Is a 0201 ALT?

At first glance, a 0201 ALT looks almost identical to a standard 0201.

The flaps are the same design.

The difference lies in how the box is manufactured.

Instead of the manufacturer's joint being positioned on the short end of the carton, it's moved to the long side.

This changes the direction of the corrugated fluting throughout the finished box.

Why Is a 0201 ALT Stronger?

Corrugated cardboard is strongest across the direction of its flutes.

By rotating the design, a 0201 ALT allows the corrugations to run across the width of the finished box rather than along its length.

For long cartons, this provides several advantages.

Increased Rigidity

The box resists bending much more effectively when lifted.

This is particularly noticeable on long, narrow cartons where flexing can otherwise become an issue.

Better Support for Long Products

Products such as cricket bats and hockey sticks create leverage inside the box.

The altered flute direction helps the carton cope with these forces much more effectively.

Reduced Flex During Transit

Long parcels are frequently picked up from one end.

The increased rigidity provided by a 0201 ALT helps reduce bending throughout the courier network.

For this reason, it's often the preferred option for longer bespoke cartons.

When Should You Choose Double Wall?

Choosing the correct box style is only part of the solution.

Board grade is equally important.

As a general rule, the longer the carton becomes, the more worthwhile it is to consider double wall corrugated board.

Double wall consists of two layers of corrugated fluting, making the box significantly stronger than single wall.

Benefits include:

• Greater rigidity.
• Better stacking strength.
• Improved puncture resistance.
• Reduced flex.
• Better protection for valuable items.

Single Wall vs Double Wall for Long Boxes

Single Wall

Suitable for:

• Lightweight umbrellas.
• Posters.
• Display materials.
• Lightweight promotional products.

Double Wall

Recommended for:

• Cricket bats.
• Hockey sticks.
• Golf clubs.
• Engineering components.
• Long fragile products.
• Heavy metal items.

Although single wall may be suitable for lighter products, double wall provides significantly greater confidence when shipping longer or heavier items.

Should You Choose a Custom Box?

Many businesses try to adapt a standard stock carton.

Unfortunately this often means:

• Excessive empty space.
• More packing paper.
• Poor product support.
• Higher courier costs.

Made-to-measure boxes solve these problems by fitting the product properly from the outset.

How ASC Direct Can Help

ASC Direct manufactures bespoke cardboard boxes specifically for long products.

Whether you're shipping sporting equipment, engineering components or promotional materials, we can manufacture cartons to your exact dimensions.

Customers can choose:

• Standard 0201 cartons.
• Stronger 0201 ALT cartons.
• Single wall or double wall board.
• Quantities from just 25 boxes.
• Production from as little as one working day.

If you're unsure which option is best, our team can recommend the most appropriate box style for your application.

Frequently Asked Questions

Is a 0201 ALT stronger than a standard 0201?

Yes.

Although the flap design is the same, the manufacturer's joint is positioned on the long side of the carton, changing the flute direction and making the box more resistant to bending.

Why does flute direction matter?

Corrugated board is naturally stronger in one direction than the other.

By altering the flute orientation, a 0201 ALT provides greater rigidity for long cartons.

Should long boxes always be double wall?

Not always.

Lightweight products may be perfectly suitable for single wall, but longer, heavier or more valuable products usually benefit from the additional rigidity of double wall corrugated board.

Final Thoughts

When shipping long products, the dimensions of the box are only part of the equation.

Choosing the correct box style and board grade can make a significant difference to how well the packaging performs throughout the delivery process.

For many long products, a 0201 ALT manufactured in double wall corrugated board offers one of the strongest and most reliable packaging solutions available.

Combined with a made-to-measure size, it helps reduce movement, minimise damage and ensure your products arrive safely every time.

James Palfrey-Smith is the General Manager at ASC Direct with extensive experience in both operations and sales. James is passionate about solving packaging problems, delivering fast customer support, and building lasting relationships. Outside of work, he enjoys outdoor activities like hiking and skiing. A fan of real ale and business podcasts, he continuously seeks personal and professional growth. 

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