The Lifecycle of a Crash Lock Box: From Flat Sheet to Finished Pack
How crash lock boxes are made, used, and recycled: the full lifecycle from forest to recycling bin.
Raw materials
Crash lock boxes start as wood pulp from managed forests (for virgin fibre) or collected waste cardboard (for recycled fibre). Most UK corrugated board contains 70-80% recycled content. The pulp is formed into flat liner sheets, and a separate fluted medium is corrugated and glued between them to create corrugated board.
Quick answer
A crash lock box goes from flat corrugated sheet to printed, die-cut, glued blank, to flat-packed delivery, to instant assembly, to product protection, to recycling and rebirth as new board. The entire lifecycle is circular: cardboard fibres can be recycled 5-7 times before being composted. This makes crash lock boxes one of the most sustainable packaging formats available.
Manufacturing process
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In use
Flat-packed boxes arrive at the fulfilment centre or business, where they are stored efficiently until needed. When an order comes in, the box is opened and the base pushed flat in seconds. Product is placed inside, the lid closed, and the parcel enters the carrier network. The crash lock base protects contents through sorting, transport, and last-mile delivery.
Learn about the manufacturing details: die-cutting and gluing processes that determine quality.
End of life
Over 80% of corrugated cardboard in the UK is recycled through household and commercial collections.
Collected cardboard is pulped and reformed into new corrugated board, completing the circular loop.
Untreated corrugated cardboard biodegrades naturally and is accepted in home and commercial composting.
Cardboard fibres can be recycled multiple times before they become too short, at which point they compost naturally.
Sustainable crash lock packaging
ProcuraPack crash lock boxes are made from recycled board and designed for full recyclability.
Browse crash lock boxesFrequently asked questions
From corrugated board through printing, die-cutting, gluing the crash lock mechanism, and flat-packing for delivery.
Cardboard fibres can be recycled 5-7 times before being composted naturally.
Yes, they arrive flat and store efficiently until needed, then assemble in seconds.
Most are recycled through kerbside collections and turned into new corrugated board.
Die-cutting produces some board waste (offcuts), but this is recycled back into the board production process.
Part of our guide
Product Guide: Crash Lock Boxes
Expert insights on crash lock packaging, from materials and design to branding and sustainability.
Browse all guides →
