Sheet Layout & Packaging Cost Calculator
Find out how many box blanks fit on a press sheet, how many sheets your order needs, and what the board costs per box. Enter your box size or open one from the studio, pick a sheet, and the calculator compares a plain grid against an interlocked 180° layout using the real dieline outline.
How the calculator works
1. Measure the real blank
The flat blank is generated from your box style, internal dimensions and board caliper, including bleed. Its exact outline, not just a bounding rectangle, is used for the layout.
2. Grid vs interlocked
A grid places bounding rectangles at 0° and 90°. The interlocked layout alternates rows at 0° and 180° and searches every horizontal offset for the tightest safe spacing.
3. Cost per box
Sheets needed include your overs allowance for make-ready and spoilage. Add a price per sheet to see board cost per box and for the whole run.
Common Press Sheet Sizes for Packaging
Folding cartons are usually printed on B1 or B2 sheets in Europe and Asia, and on 28 × 40 in or 25 × 38 in sheets in North America. Short digital runs use SRA3 or 13 × 19 in. Larger sheets lower the cost per box when the run is long enough to justify the make-ready.
| Sheet | Millimetres | Inches |
|---|---|---|
| B1 | 1000 × 700 | 39.4 × 27.6 |
| B2 | 707 × 500 | 27.8 × 19.7 |
| 28 × 40 in | 1016 × 711 | 40.0 × 28.0 |
| 25 × 38 in | 965 × 635 | 38.0 × 25.0 |
| 20 × 28 in | 711 × 508 | 28.0 × 20.0 |
| SRA3 digital | 450 × 320 | 17.7 × 12.6 |
| 13 × 19 in digital | 483 × 330 | 19.0 × 13.0 |
How to Fit More Boxes on a Sheet
- Pick a structure that nests. A straight tuck end carton usually interlocks more tightly than a reverse tuck end, because both closures sit on the same panel.
- Trim a few millimetres. A blank that is just over a sheet fraction loses a whole row or column. Try the box 2–3 mm smaller and watch the ups count.
- Reduce bleed and gutter where your printer allows. Common-line cutting (0 mm gutter) lets neighbouring blanks share a cut rule.
- Match board to weight. Thicker board raises the price per sheet. See the paperboard caliper guide before upgrading.
Frequently Asked Questions
What does "ups per sheet" mean?+
Ups is the number of box blanks that are printed and die-cut together on one press sheet. More ups means fewer sheets, less make-ready time and a lower cost per box.
What is an interlocked (nested) layout?+
Alternate rows are rotated 180° so the tuck flaps and dust flaps of one blank fit into the gaps of its neighbour. For tuck-end cartons this often fits 10–30% more blanks than a plain grid of bounding boxes.
What are the gripper and gutter?+
The gripper is the unprintable leading edge the press uses to pull the sheet, typically 8–12 mm. The gutter is the gap left between neighbouring blanks so the cutting rules do not touch; 0–3 mm is common, depending on whether blanks share cut lines.
How is board cost per box calculated?+
Sheets needed = quantity × (1 + overs %) ÷ ups, rounded up. Board cost per box = sheets needed × price per sheet ÷ quantity. Printing, die-making, gluing and freight are quoted separately by your printer.
Is the layout ready to send to a die-maker?+
It is a reliable planning estimate that uses the real blank outline, so blanks never overlap. Your printer or die-maker will finalise grain direction, common-line cutting and stripping before making the die.
Design the box, then plan the run
Create a custom dieline with live 3D folding, then export print-ready PDF, SVG and DXF.