Where Packaging Fails—and How to Fix It (II)
In our previous post, we covered three common breakdowns and how to avoid them. Today, we’re tackling three more pain points that quietly drain time and margins:
Off-the-Shelf Misfit, Inconsistent Supply, and Changeover Pain when you’re trying to improve workflow without slowing the business.
1) Off-the-Shelf Misfit
The pain: Standard parts rarely match real-world constraints—your board stack, flute, cutout geometry, load case, or ergonomic targets. Teams “make it work” with extra tape, ad-hoc cuts, or awkward installs that create failure points later.
Fix the root cause: Design for your exact needs.
Allen Field offers clips, reinforcements, and carry handles sized to your board thickness and use case. We fit parts to your material, check clearances, ensure the load is supported correctly, and confirm with pilot samples—so when you scale up, there are no surprises.
Operational wins: Easier installs, fewer workarounds, repeatable performance—and a package that behaves the same on a Tuesday afternoon as it does during peak.
2) Inconsistent Supply
The pain: Offshore delays and sourcing disruptions create production risk. Lead times slip, schedules shuffle, and teams burn time chasing parts instead of building product.
Fix the root cause: Diversify sources and standardize on spec-true parts you can get reliably.
Allen Field supports multi-source availability and domestic stocking on core clips, handles, and display hardware—so you’re not waiting on a single lane. We help you cross-reference equivalents, lock in forecast-based inventory, and set pilot kits so critical builds aren’t held up by missing components.
Operational wins: More predictable schedules, fewer line stoppages, faster recoveries—and less time firefighting.
3) Changeover Pain
The pain: New components often require engineering support most suppliers don’t provide—so teams hesitate to make changes even when the ROI is obvious. CAD redraws, spec confusion, and training gaps stall adoption.
Fix the root cause: Remove roadblocks with tools and support.
- CAD-native parts: Allen Field components are natively available in Esko ArtiosCAD (Nov ’25 release), so you can drop clips, handles, and aids into 3D and auto-sync your dieline to spec.
- Selection guides & sample kits: Quick sizing tools, curated sample packs, and test protocols shorten validation.
- Process-ready hardware: Tool-free box connecting clips for repeat access (QA/returns), clips and corners for flap control, hand-hole protectors for safer lifts, and semi-auto EnviroHandle applicators for speed and consistency—without a full automation overhaul.
Operational wins: Faster changeovers, fewer reworks, quicker time-to-value—and a confident switch you can scale.
Ready to move?
When hardware fits and holds, boxes stay intact, shelves stay tidy, and lines keep moving. You protect the product and the box—reducing waste, lowering costs, and improving the experience for customers and teams.
Build a line that flows, not fights. With the right components—and a partner who supports the switch—you protect the product, preserve the box, and improve the experience end-to-end.
Where Packaging Fails—and How to Fix It (I)
Three common breakdowns (and the hardware that stops them): transit damage, messy retail presentation, and assembly bottlenecks.
Packaging failures rarely start as big problems. They start as small mismatches: hardware that doesn’t quite fit, closures that slow access, hooks that don’t hold under load. Left alone, those mismatches become returns, rework, and lost sales. Here’s how to address the root causes with purpose-built components.
1) Damage in Transit: When Fit and Hold Fail
The pain: Boxes open, panels bow, and products shift or break. Tape and strapping hide the issue for a moment, then create new ones—knife hazards, scarred cartons, and slower receiving.
Fix the root cause: use spec-true structure and carry.
- Box connecting clips, panel stabilizers, and reinforcement clips keep geometry tight and joins secure—without single-use strapping.
- Hand-hole protectors and ergonomic handles distribute load across the corrugated panels, reduce tearing at cutouts, and guide proper lifts.
Operational wins: fewer damages and returns, faster checks at the dock, cleaner cartons that can be reused in reverse flows.
2) Retail Presentation Breakdowns: When Hardware Doesn’t Hold the Look
The pain: Hooks slip, hangers bend, and facings go crooked. Staff spend time rehanging instead of helping customers, and shelves look tired even when product is great.
Fix the root cause: spec for alignment and load.
- Precision-designed plastic hooks and hangers hold steady, keeping products planogram-aligned.
- Kraft hangers & hooks provide a paper-based alternative that supports sustainability goals while maintaining clean presentation.
Operational wins: tidier facings, faster resets, fewer fixes—and a better shopper experience that protects sell-through.
3) Assembly Bottlenecks: When Traditional Materials Slow the Line
The pain: On the manufacturing line, during shipment prep, at QC, or in returns—tape, strapping, and blades interrupt flow. Teams fight flaps, cut and re-tape boxes, and create preventable rework.
Fix the root cause: make access repeatable.
- Innovative box connecting clips facilitate assembly and allow clean open/close, again and again, without damaging cartons.
- Because access is tool-free and repeatable, teams move faster across build, inspection, and return loops.
Operational wins: less labor, less rework, faster throughput—and carton boxes that survive multiple cycles.
Explore products that streamline assembly, QC, and returns.
How to Choose the Right Mix
- Map the friction: transit, retail, process—or a combination.
- Stabilize structure first: select the right fastener/reinforcement for your corrugated panels.
- Distribute the load: add handhole protectors or handles to protect cutouts and workers.
- Match the display task: choose solutions that are secure, ship-ready, floor-ready, and user-friendly—while adding brand value.
- Pilot and measure: track damages, rework minutes, and return condition to validate the change.
The Payoff
When hardware fits and holds, boxes stay intact, shelves stay tidy, and lines keep moving. You protect the product and the box—reducing waste, lowering costs, and improving the experience for customers and teams.
Design for fit. Ship with confidence. Present with clarity. Keep the line flowing. With the right components, you can do all four.
December 2025
Repeatable access. Gap-free closure. Ergonomic carry.
Base Skid Joint
Secure an outer corrugated cover directly to the pallet with the PP400WL—a reusable, secure connection with no strap scars and no blades.
Compare to strapping:
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Repeatable access — open and reclose as needed
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Faster handling at packing, QA, and receiving
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Cleaner presentation — no crushed corners or marks
Great for: open-bottom outer covers, dust/dirt mitigation, WIP, and light distribution.
Large Hand Hole Protector Clip
The PP901WP2 Clip connects two corrugated boards while providing reinforced hand holes for easier, safer carrying. The interlock speeds access to contents, and the hatch keeps dust and debris out.
Compare to strapping:
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Strong, ergonomic carry — no digging straps; reinforced openings resist tear-outs
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Fewer hazards — reduces cut risks and awkward lifts from sharp straps
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Cleaner access — interlock opens fast; no cutting or removing strapping
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Debris control — integrated hatch keeps dust out
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Clear orientation — “UP” arrow speeds handling and QC
Box Clips with Fixed Paddle
Clips in our Fixed Paddle Series tighten inner and outer panels, removing gaps for a cleaner, stronger result.
Compare to strapping:
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Prevents strap scars and reduces blade use
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Gap-free hold for tighter, stronger edges
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Repeatable access — open and reclose as needed
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Tool-free install — quick to apply and remove
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Reusable clip for truly reusable packaging
Thank you to our customers for your trust this year—and to the Allen Field team for the ingenuity and care behind every solution. Wishing you a safe, joyful holiday season and a strong start to the new year.
Happy Holidays!
Prevent Damage & Protect What’s Inside: Designing Packaging That Holds Up
Strapping marks on cartons. Crushed panels. Internals that shift or break in transit. Boxes that pop open or tear during handling. These aren’t “costs of doing business”—they’re signs that the load path, closure method, or carry system isn’t matched to the job. The good news: small hardware choices can eliminate most of these headaches while improving speed, safety, and presentation.
Below, we break down why damage happens and how to stop it—at the source.
Where Damage Starts and How It Spreads
- Strapping cuts into cartons. When tension is doing the holding, cardboard takes the punishment. Over time you see strap scars, edge crush, and panel bowing.
- Boxes bow or pop open. If the closure relies on tape alone—or flaps are working against the operation—pressure finds the weak point.
- Internal components shift. Without stabilization, parts migrate, rub, and break. Even minor movement can mar finishes or misalign kits.
- Packaging tears during handling. Raw hand holes concentrate force at a thin edge; repeated lifts tear fibers and fatigue the wall.
- Panels separate under load. Loads that aren’t transferred across the wall or reinforced at stress points will peel or delaminate under normal handling.
Fix the Root Cause with the Right Tools
Clips & Connectors: Control the Structure
Allen Field’s clips and connectors do the quiet work of stabilizing joins and managing load paths so the carton—not the tape—carries the day.
- Box connecting clips create reliable, reusable closures that open and reclose cleanly for QA, replenishment, or returns—without knives or re-taping.
- Panel locks and stabilizers keep walls aligned and resist bowing so boxes don’t “smile” under tension.
- Reinforcement clips add strength right where corrugated is most vulnerable—at corners, seams, and cutouts.
- Reclose inspection clips enable repeated access without destruction, protecting both product and box.
Result: fewer strap marks, tighter geometry, less rework, and boxes that remain serviceable across multiple touchpoints.
Carrying Solutions: Shift the Load, Save the Box
A handle is a load-distribution device as much as it is a grip. Our handles and hand-hole protectors spread force across the wall, protect cutouts, and guide proper lifting.
Result: safer carries, cleaner presentation, and fewer failures that lead to returns.
Custom Options: Reinforce Where Your Box Needs It
Some programs demand tailored reinforcement. We engineer custom components that target weak zones and control load shift inside the carton—particularly useful for kits, multi-SKU packs, and delicate assemblies.
Result: internals stay put, surfaces stay pristine, and the unboxing feels intentional.
Operational Wins You’ll Notice
- Less damage and fewer returns. Stabilized structures and controlled access reduce failure points.
- Faster, cleaner workflows. Reopen/reclose without knives or tape; operators stay in flow.
- More reuse cycles. When boxes aren’t torn up by straps and blades, they live longer in return, QA, and replenishment loops.
- Better brand experience. No strap scars or crushed panels; products arrive ready, and unboxing feels premium.
- Sustainability with ROI. Reduced waste from scrap cartons and rework, plus hardware designed for reuse.
Selecting the Right Mix
- Map the pain. Where do damages or slowdowns happen—on the line, in transit, at shelf, or in returns?
- Choose the primary control. If closures fail, start with box connecting clips; if walls bow, add panel locks/stabilizers.
- Reinforce the lift. If carries cause tears, add a handle or hand-hole protector to distribute force.
- Stabilize the inside. Use reinforcement clips or custom internals to stop movement at the source.
- Pilot and measure. Validate with a short run; track rework time, damages, and return rates.
Real-World Use Cases
- E-commerce & returns: Reclose clips allow inspection and restock without destroying cartons—clean boxes return to the floor faster.
- Club & promo packs: Handles reduce wall strain on heavy multipacks; reinforcement clips prevent bowing during pallet moves.
- Kitting & assembly: Panel locks and stabilizers preserve geometry so kitted parts don’t shift or rub.
- QA & replenishment: Reopen/reclose hardware keeps teams moving—no time lost to re-taping or hunting for cutters.
Ready to Prevent Damage—and Protect What’s Inside?
Allen Field’s clips, connectors, handles, and reinforcements are engineered to solve specific failure modes with minimal process friction. Tell us your pain points; we’ll help you spec a set of components that defends both the product and the box—end to end.
Protect the product. Preserve the box. Improve the experience. With the right hardware, you can do all three.
November 2025
Designing to spec just got easier. Allen Field’s clips, handles, and POP display aids are now natively available in Esko ArtiosCAD, so packaging designers and engineers can drag-and-drop real components into their dielines—no guesswork.
What this unlocks
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Design faster — drop in spec-accurate components, instantly
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Cut rework — precise geometry delivers cleaner cuts and better fit
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Align teams — consistent files from CAD to production
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Waste less — tighter tolerances reduce scrap
Read the press release and explore our products.
Product Spotlight
TL15 Twistlok Clip
The TL15 Twistlok Clip is a reusable fastener engineered to secure two joining panels with a combined wall thickness of 0.59″ (15 mm). Its twist-to-lock mechanism pushes through two layers of corrugated and locks firmly in place, while four inner tabs eliminate gaps between inner and outer panels for a tight, reliable hold.
Why it’s useful
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Tool-free & tape-free: installs and removes quickly with a simple circular cutout—no sharp tools or adhesives.
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Reusable by design: supports more sustainable, efficient packing processes.
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Clean, consistent fit: secure closure that stands up to handling and rework.
Press Release: Allen Field Co., Inc. Components Selected for Esko ArtiosCAD 3D Component Library
November 13, 2025 at 20:01 PM EST
BENSALEM, Pa. – Nov. 13, 2025 – PRLog — Allen Field Co., Inc., a leading provider of innovative packaging components and solutions for the structural packaging industry, today announced its selection by Esko as an approved component partner in the ArtiosCAD 3D component library. The addition, featured in Esko’s latest product release (ArtiosCAD 25.11), represents a significant competitive distinction and validates Allen Field’s commitment to supporting the packaging industry’s digital design ecosystem.With Allen Field components, including box clips, handles, and other critical handling components, now officially available in ArtiosCAD’s library, packaging designers and manufacturers can access verified, production-ready Allen Field specifications directly within the industry-standard structural design software. This selection reflects Esko’s confidence in Allen Field’s product specifications, quality standards, and commitment to supporting integrated digital workflows.How to Reduce Packaging Design Cycle Time with Integrated Component LibrariesArtiosCAD is recognized across the packaging industry as the leading structural design software, with widespread adoption among packaging professionals, design firms, and in-house design teams. By adding Allen Field components to the ArtiosCAD 3D component library, the integration enables designers to:
- Select Allen Field components from within the ArtiosCAD design interface and automatically incorporate them into packaging designs
- Access precise component specifications and geometry data directly from the design environment
- Automatically sync 2D structural design files with official Allen Field component specifications, eliminating manual data entry and reducing errors
- Accelerate prototyping cycles by accessing verified, production-ready component information during the initial design phase
“Being selected for inclusion in Esko’s ArtiosCAD component library is a significant recognition of Allen Field’s commitment to quality and digital integration,” said Robert Ahearn, vice president of marketing and sales at Allen Field. “This partnership validates our approach to supporting designers where they work and ensures that Allen Field components are a seamless choice in the packaging design workflow. It’s a rare distinction in our industry, and we’re proud to be part of Esko’s ecosystem.”
Gaining Competitive Advantage Through Digital Ecosystem Participation
One of the key advantages of official inclusion in the ArtiosCAD library is immediate visibility and credibility at the critical moment when packaging specifications are defined. Because Allen Field components are now part of Esko’s official component library, designers recognize them as validated, production-ready options and can select Allen Field components at the moment sourcing decisions are being made.
The official integration also reduces the risk of design-to-production mismatches and rework, ultimately lowering costs and improving supply chain efficiency. For in-house design teams, this translates to faster design cycles and reduced dependency on manual component specification lookups. For design agencies and packaging consultants, it represents an opportunity to enhance client deliverables with verified, production-ready component data. For brand owners and retailers, it contributes to more reliable packaging specifications that support efficient supply chain execution.
About the Integration of Allen Field Components into the Esko ArtiosCAD Database
The Allen Field component library in ArtiosCAD includes the company’s most widely used structural components, with plans for continued expansion. Designers using ArtiosCAD can access the components through the standard component library interface. For more information about ArtiosCAD 25.11 features, visit Esko’s product release announcement at www.esko.com/en/blog/25-11-whats-new.
About Allen Field Co., Inc.
Allen Field Co., Inc. specializes in providing innovative, high-quality, sustainable packaging components. With over 500 stock parts and a 9.7 customer approval rating, Allen Field has proven its commitment to exceptional service and leverages its innovative culture to collaborate with clients in ways that create maximum value. For more information, visit https://www.allenfield.com
Photos: (Click photo to enlarge)
Source: Allen Field Company
Read Full Story – Allen Field Co., Inc. Components Selected for Esko ArtiosCAD 3D Component Library
Allen Field Components Are Now Built Into Esko’s ArtiosCAD — What This Means for Your Workflow
Esko’s November 2025 ArtiosCAD release now includes official Allen Field packaging components inside the software. For packaging teams, that means you can place our clips, handles, reinforcements, and display aids directly into 3D designs and see your 2D structural files update automatically—no redrawing, no guesswork, and far fewer back-and-forths.
Seamless integration, fewer steps
Instead of hunting for specs, recreating geometry, or maintaining local libraries, designers can select Allen Field parts from within ArtiosCAD and drop them straight into the design. Alignment and placement are handled in the 3D environment, and the dieline reflects those choices immediately. This removes manual work and reduces the opportunities for error that creep in when specifications are re-entered by hand.
Faster design time, tighter handoffs
With precise Allen Field models available in the 3D workflow, fit checks happen earlier and with more confidence. When you change a component or position in 3D, the 2D file syncs to match the official dimensions—cutouts, holes, and locations stay true to spec. The result is shorter iteration cycles, cleaner cut files, and fewer surprises on the production floor.
Design with confidence
Because the ArtiosCAD library now includes Allen Field’s official geometry, compatibility questions largely disappear. You’re working from the same authoritative dimensions our engineering team uses, so you can expect cleaner installs, less scrap, and a higher first-time-right rate once designs move into fabrication and packing.
Who benefits
Designers get faster placement and fewer redraws. Manufacturing and operations improve consistency and assembly speed thanks to spec-accurate cutouts. Quality and engineering gain traceability and easier audits because the same data underlies both the design and the component in use.
Quick Start: How to Use It
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Open ArtiosCAD (Nov 2025 release or later).
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Browse the Allen Field component library and select the part you need.
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Place the component in 3D to validate fit and interaction.
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Sync your 2D file—cutouts and alignment update automatically.
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Export and release to production with confidence.
Why this changes the day-to-day
Teams spend less time passing spreadsheets and clarifying dimensions, and more time building the right solution. Prototyping accelerates, rework declines, and lines install hardware with fewer adjustments. When combined with Allen Field’s broader portfolio—reusable closures, ergonomic hand-hole protectors, and kraft-based solutions—the CAD integration helps you deliver smarter, stronger, and more sustainable packaging with less friction.
Ready to design to spec?
October 2025
PACK EXPO Recap — Thank You for a Great Show!
We had a successful PACK EXPO Las Vegas—thank you to everyone who stopped by.
Our standout demo was the semi-auto applicator for EnviroHandles, engineered for speed, consistent placement, and clean, brand-ready finishes on boxes up to 40 lbs. By automating a traditionally manual step, teams cut install time, lower labor costs, and boost throughput—while supporting sustainability with recyclable paper handles.
Attendees praised the easy integration, ergonomic benefits, and repeatable, professional results. If you missed us at the show, we’d be glad to walk you through how the applicator fits your line and ROI goals.
Another crowd favorite was our Box Latch® line—reusable closures (Medium, Large, and Twist Latch) that replace tape and staples, reduce waste, and speed WIP and changeovers across the warehouse and line. Use color coding to signal destinations, processing stages, or handling instructions—bringing clarity to even the most complex workflows.
Coming Nov 4th: Design to Spec, Build with Confidence
Designing to spec matters. Precise CAD and consistent die line cuts mean faster installs, less scrap, fewer reworks—and ultimately less waste.
Starting November 4, Allen Field’s box clips, carry handles, and POP display aids will be natively available in a leading CAD/die line platform. Drop our components directly into your designs for cleaner cuts, better fit, and smoother production—no extra guesswork. Stay tuned for the full reveal.
What you’ll gain
- Faster setup and installs
- Tighter tolerances, fewer reworks
- Reduced scrap and waste
Rotary Clips-twist to lock and unlock in seconds
Tape-On Paper Handle- seamless single-stream recyclability
PP901 – reinforces handholes and installs/removes fast
Why Easy-to-carry Packaging Sells and Keeps Teams Safer
Ever picked up a boxed printer or sample kit and thought, “Nice—this feels right”? That’s not luck. It’s the quiet ROI of easy-to-carry packaging.
What a Handle Really Does Beyond Carrying
A handle is a nudge. At retail, it signals “take me now”—especially on bulky items. In operations, it tells teams how to lift. Do both well, and you get fewer drops, fewer repacks, and a smoother line.
- Shelf impact: A visible, comfortable grip lowers the “ugh” factor for heavy purchases.
- Brand experience: Clean unboxing—no ripped hand holes, no wrestling with strapping—earns trust.
Ergonomics You Can Feel
Small placement changes make a big difference. A well-positioned handle aligns wrists and shoulders, which reduces strain and helps prevent injuries.
- Lift vs. pull: Corrugated hand holes are for lifting, not pulling. Add a hand-hole protector and the force spreads out—so teams (and shoppers) can pull or lift without tearing the box.
- Fewer slowdowns: When packaging behaves, lines keep moving and rework falls off.
Why Some Handles “Just Work”
A lot is happening inside that “simple” part:
- Strength + flexibility: Many components rely on living hinges—they need to flex repeatedly without cracking.
- Proven durability: Parts are tuned to pass common performance tests (e.g., drop and handling).
- Material match: Resins and recycled content levels are chosen to keep clips locking, hinges flexing, and grips comfortable.
Pick What Fits Your Program
Different goals, different paths. No one-size-fits-all here.
- Recyclable plastics: The vast majority of our components are curbside-recyclable, which is a practical win for mainstream recovery.
- Recycled content that performs: With cleaner supply streams, many SKUs run up to ~50% recycled content while meeting strength and hinge requirements.
- Paper when you need it: Have a “no plastic” mandate? Our 100% paper handle with a fabric strap glues on and is pulpable with the box—no removal step.
The Hidden ROI of Easy-to-Carry Packaging Design
- Fewer returns: Reinforced openings and box-connecting clips keep cartons intact, which cuts damage and reverse logistics.
- Safer lifts: Correct grip points reduce awkward motions and fatigue.
- Faster changeovers: Components designed for quick seating and repeatable cutouts keep lines efficient.
- Happier unboxing: Smooth releases and intact panels support premium brand moments.
A Simple Checklist for Your Next Carton
- Path of travel: Will anyone pull the box? If yes, add hand-hole protection.
- Carry distance: Longer carries need user-friendly contours and firm, stable grips.
- Board + cutout: Confirm cutout specs and board strength match handle load.
- Reuse potential: If the box will be reused for storage, choose durable components.
- Sustainability claim: Decide early—recyclable plastics, recycled content, or pulpable paper—and align the spec to the claim.
Want a quick fit-for-purpose review? Send your current carton specs and target claims; we’ll recommend a component path that balances comfort, durability, and sustainability.
September 2025
Heavy Duty Auto Handle
Built for Speed, Designed for Safety, Proven to Save.
If labor costs have kept you from adding plastic handles, the HD Auto Handle changes the equation—delivering a faster, more cost-effective path to premium packaging.
Built for speed, the HD Auto Handle installs quickly by hand and even faster with a collaborative robot—cutting installation time and keeping product moving on both manual and automated lines.
Why it wins
- Faster installs, higher throughput
- Manual and cobot-ready
- Cut labor and strain
- Consistent placement, improved QC
- Carry up to 60 lbs. without a backing plate
Speed up. Stay Safe. Save money.
See It in Action at PACK EXPO
@ Booth #SU-38000
September 29 – October 1, 2025 | Las Vegas, NV
Explore efficient, automation-ready components in Las Vegas—recyclable, reusable, and ready to perform from warehouse to customer. Register free with code 51K62.
Product Gallery
Visit our Product Gallery for quick demos and how-to videos—installation tips, side-by-side comparisons, and more in one place. It’s the fastest way to see our components in action and find the right solution for your packaging challenge.
Elevate Packaging Design with Box Connecting Clips
Increase Strength and Stability for Larger & Heavier Packaging
Attach Corrugated Cover Directly to Pallet without Strapping
August 2025
EnviroHandles + Automation
Designed for boxes up to 40 lbs, this semi-automatic system applies our EnviroHandles with precise placement and consistent alignment—delivering efficiency and sustainability in one solution.
Benefits:
- Eco-friendly – 100% natural paper or fabric handles support your sustainability goals.
- Efficient – Automates a manual process, cutting labor fatigue and training needs.
- Professional finish – Every package looks polished and brand-ready.
- Production-ready – Increases throughput for small to mid-volume runs without major modifications.
With EnviroHandles + Automation, you get a packaging solution that’s smarter for your team, stronger for your brand, and better for the planet.
See It in Action at Booth #SU-38000
at PACK EXPO Las Vegas
September 29 – October 1, 2025 | Las Vegas Convention Center
Explore Allen Field’s latest innovations at PACK EXPO Las Vegas! From sustainable plastic components to all-natural, single-stream recyclable alternatives, plus our automation system in action—you won’t want to miss it. Register free with comp code 51K62.
BC350 Rotary Bayonet Clip
Looking for a faster, smarter way to secure telescoping corrugated packaging? The BC350 Rotary Bayonet Clip locks and unlocks in seconds—just slip, twist, and rotate. Designed to stay attached even after disengagement, it saves time, reduces loss, and supports sustainability with full reusability.
- Size: 4.00″ Diameter
- Max. Board Thickness: 0.37″
- Sustainable Features: Reusable / Recyclable / Recycled Content / Biodegradable
Slip the clip through the cutouts and twist into place.
Rotate to lock or unlock as needed.
Clip stays attached to the box, even after disengagement.
Press Release: Allen Field to Showcase Sustainable Paper Handle Applicator at PACK EXPO Las Vegas 2025
LAS VEGAS – August 26, 2025 – Allen Field Co., Inc., a problem-solving packaging partner with over 40 years of industry leadership, will debut its innovative semi-automatic sustainable paper handle applicator at PACK EXPO Las Vegas. Designed for packaging up to 40 lbs, this solution combines sustainability with efficiency, helping brands meet environmental goals without sacrificing performance.
The system is engineered to apply Allen Field’s recyclable paper handles with precise placement and consistent alignment, ensuring a professional, brand-enhancing finish on every box. By automating what is traditionally a manual process, the applicator reduces worker fatigue, minimizes training requirements, and increases throughput, making it an ideal fit for small to mid-volume production.
“This machine was developed with real-world use in mind,” said Robert Ahearn, Vice President of Sales and Marketing at Allen Field. “Our customers wanted an easy-to-integrate solution that doesn’t require major modifications — and we delivered just that.”
Flexible Options for Any Operation
While the semi-automatic applicator will be demonstrated live at the show, Allen Field also offers a fully automated handle application system for operations with the highest throughput demands. The automated model delivers up to 11,000 handle applications per hour and integrates directly into high-speed existing box folding lines.
Unlike the semi-automatic model, the fully automated system is not a quick-install solution. It is provided with factory-direct professional installation to ensure optimal performance and is compatible with most existing brands of folding/gluing machines. This turnkey integration ensures maximum efficiency, speed, and placement accuracy at full production pace.
For companies not yet operating at that scale, the semi-automatic option offers the same accurate placement and professional finish, while giving flexibility for smaller production runs and significantly reducing the labor of manual application. It will also be available to rent for projects, giving companies a cost-effective way to run short-term or seasonal programs without the need for a full equipment purchase. The semi-automatic unit requires only a standard air connection and a 220v electrical hookup to operate, allowing for quick setup in most facilities.
Sustainability Without Compromise
The paper handles applied by these systems are 100% recyclable, and some styles are also repulp able, allowing them to be reprocessed into new paper products without contamination. This gives brands flexibility in meeting various recycling and sustainability standards while offering a strong, comfortable carrying solution for packages up to 40 lbs.
Allen Field also offers sustainable plastic handle options, which have long been favored for their durability, reusability, and design-for-disassembly features. These components can extend packaging life, reduce the need for secondary materials, and are compatible with recycling streams where infrastructure exists. By replacing single-use elements with reusable hardware that protects product integrity, our plastic solutions often lower total environmental impact over the product’s lifecycle — a key factor in many brands’ sustainability strategies.
See It in Action at PACK EXPO – Booth SU-38000
Visit Allen Field at PACK EXPO Las Vegas, September 29–October 1, booth SU-38000, to watch the sustainable paper handle applicator in operation and discuss the fully automated option. Our team will help you determine which solution best fits your production volume, workflow, and sustainability goals.
About Allen Field Co., Inc.
Allen Field Co., Inc. specializes in providing innovative, high-quality, sustainable packaging components. With over 500 stock parts and a 9.7 customer approval rating, Allen Field has proven its commitment to exceptional service and leverages its innovative culture to collaborate with clients in ways that create maximum value. For more information, contact us!
