Oversized Boxes: A Global Packaging Trend
The global packaging industry is undergoing a transformation. With the rapid growth of e-commerce, global exports, and especially home appliance and electronics sales, manufacturers are facing a new challenge: how to pack big, heavy products safely, efficiently, and sustainably.
Whether it’s a 75-inch TV, a washing machine, or an air conditioner — all these bulky items need strong, oversized corrugated boxes for protection during transit. As a result, the demand for large-format packaging is growing faster than ever.
Market Insights
• The global corrugated box market is projected to grow from $171.4B in 2024 to $269B by 2033
• The heavy-duty corrugated segment alone is expected to reach $12.2B by 2030
• Global home appliance sales are expected to exceed $1.2T by 2032
• Nearly 900 million major appliances will be shipped worldwide in 2030
• E-commerce is driving new demand for shipping large, fragile products directly to consumers.

These big products need big boxes—durable, stackable, and often custom-configured. Corrugated cartons meet the need: they’re strong, recyclable, and lighter than traditional wooden crates. Their popularity is also being driven by stricter sustainability targets and rising global logistics activity.
But as demand rises, packaging manufacturers face new challenges: producing larger, more complex boxes quickly and affordably, without compromising precision or quality. Traditional folder gluers can’t always keep up.
The Packaging Technology of Tomorrow, Ready Today

The T-Fold Pro by DGM is built specifically to meet this challenge. Designed for high-speed, high-precision production of oversized corrugated cartons, it brings together advanced automation, material efficiency, and remarkable versatility in one intelligent machine.
At the heart of the T-Fold Pro is a dual feeder system that allows two corrugated blanks to be processed simultaneously. These are precisely aligned and joined to form a single, extra-large carton—without requiring manual intervention or secondary assembly steps. The process is continuous, reliable, and perfectly suited for high-volume production environments.
A major innovation lies in the machine’s left-right dual splicing method, which replaces traditional overlap flaps with edge-to-edge joining. This not only saves on board material but also reduces the overall machine footprint. It’s an elegant solution that improves both workflow and cost efficiency—especially for companies producing large boxes in limited floor space.
The system is fully servo-driven, with real-time registration, automatic alignment, and an intuitive touchscreen interface. Operators can set, adjust, and recall job parameters quickly, minimizing downtime and boosting output. Despite its technical depth, the machine is user-friendly, stable, and dependable—even with thick, heavy corrugated board.
Beyond oversized RSC boxes, the T-Fold Pro is built to handle complex packaging styles, including TwinBox designs, lock-bottom boxes, and wine cartons with partitions. It supports integration with DGM’s MegaFold or Colt systems to create a full inline packaging line—from feeding to gluing to bundling—all in one seamless process.



Key Advantages of the T-Fold Pro:
• Dual Feeder System: Simultaneously processes two blanks for oversized box production.
• Left-Right Splicing: Edge-to-edge joining reduces material waste and machine length.
• High-Speed Automation: Servo-driven, user-friendly system ensures accuracy and efficiency.
• Multi-Format Capability: Handles twin boxes, partitions, lock bottoms, and more.
• Scalable Integration: Works offline or in line with MegaFold and Colt for full automation.

The result is a system that doesn’t just produce boxes—it optimizes your entire production cycle. By reducing manual labour, saving materials, and improving speed and accuracy, the T-Fold Pro enables packaging manufacturers to respond to growing market demand without compromising profitability or precision.
Whether you're producing for global exports, bulk retail, or heavy-duty logistics, the T-Fold Pro delivers the automation, reliability, and performance your operations require—today and into the future.
Interested in transforming your large-format packaging line?
Contact us today for more information and a live demo.
Post time: Apr-18-2025