Our edge

CartoNova’s BoxBuilder and accompanying FEA-based simulation suite allow you to prototype and validate carton designs virtually before committing to tooling. You can adjust flute profiles (A, B, C, E-flute), board grades, and multi-panel crease placements, then run compressive strength and drop-test simulations under UK warehouse humidity profiles. Detailed output reports include safety factors, maximum stacking heights, and predicted damage rates—enabling data-driven decisions that reduce material usage by up to 25% while ensuring product protection.

We provide cradle-to-grave lifecycle assessments (LCA) for dozens of common carton materials—virgin vs. recycled corrugated, coated vs. uncoated boards, bioplastic window films—using UK-specific energy grids and waste-management data. Our Sustainability Dashboard quantifies CO₂-equivalent emissions, water footprint, and end-of-life recyclability. Users can compare scenarios—e.g., switching to 100% recycled board or adopting water-soluble coatings—and instantly see environmental and cost trade-offs, supporting corporate-ESG reporting and compliance with UK Plastics Packaging Tax exemptions.

Our Prototype Lab service transforms your digital die-lines into real-world mock-ups within 48 hours. We use high-resolution laser cutting and FDM 3D printing to produce accurate scale models for fit-and-function checks. Physical drop, vibration, and compression testing in our London facility validate virtual simulations. Detailed test reports document failure modes and recommend reinforcements. This iterative cycle—design, prototype, test—accelerates development timelines and reduces costly re-tooling on the production floor.

Beyond structure, CartoNova helps you craft compelling brand experiences through print and finishing techniques tailored to UK market tastes. Our Graphic Studio guides cover registration-perfect dieline layout, spot-UV application on kraft board, eco-friendly UV-LED varnishes, and metallic cold-foil accents. We detail substrate-ink adhesion tests, drying-time optimisation, and colour-management workflows compliant with ISO 12647-2. Unboxing-experience case studies demonstrate how tactile liners, custom tissue wraps, and integrated brand storytelling boost customer satisfaction and social-media engagement.

We offer best-practice guides on integrating carton specifications into ERP and warehouse-management systems. Our API-ready specification templates ensure that box dimensions, board grades, and print files flow seamlessly from design to order-management to 3PL execution. Cost-model calculators incorporate material, tooling amortisation, printing, and transport charges—enabling you to compare regional UK converters, negotiate volume discounts, and identify zone-skipping opportunities for distribution hubs.

CartoNova keeps you ahead of evolving UK packaging regulations—UK Packaging Waste Regulations, Extended Producer Responsibility (EPR) requirements, Plastics Packaging Tax. We provide compliance checklists, template declarations, and step-by-step guidance on registering with environmental agencies. Our legal-reviewed white papers interpret upcoming changes, such as recycled-content mandates, helping you adapt designs and supply-chains proactively.