Leather boxes are a versatile choice for packaging board games, known for their varied designs and intricate craftsmanship. Made from materials such as leather, velvet, and grayboard, leather boxes offer unique benefits over traditional paper boxes. This article explores the unique aspects of leather boxes, compares them to paper boxes, and details their comprehensive manufacturing process.
Leather Boxes vs. Paper Boxes
Delivery Time: Leather boxes typically require 25 to 35 days for delivery, whereas paper boxes can be delivered in about 14 days.
Odor: Leather boxes may have a stronger odor compared to paper boxes.
Assembly Complexity: Leather boxes are more complex to assemble than paper boxes.
Durability: Leather boxes are more resistant to deformation and mildew than paper boxes. They are water-resistant, anti-mildew, insect-resistant, and highly durable.
Design Versatility: Leather can be combined with materials like iron, bamboo, and plastic, allowing for diverse and unique designs.
Detailed Leather Box Manufacturing Process
1. Design & Quotation
Objective: Confirm materials, processes, and quotes with the customer based on the leather box's purpose and testing requirements.
Key Points: Specific structures and processes must be confirmed multiple times as prices can vary significantly.
2. Prototyping
Equipment: Laser cutting machine, V-groove machine, cutting machine, punch press.
3. Mold Making
Objective: Create the necessary molds for mass production.
Time Required: Generally 4-12 days; complex molds can take up to 15 days.
4. Material Preparation
Objective: Prepare the necessary raw materials based on the confirmed sample.
Time Required: Procurement cycle generally takes 12-15 days, longer for special colors.
5. Production
Objective: Complete the main parts' production in the factory.
Common Materials: Leather, velvet, gray board.
Capacity: Production output of approximately 200,000 units in 40 days (22 production lines).
Process Steps: Material cutting, paper board pressing, gluing, stitching, shaping.
Key Points: Leather boxes require significant manual labor, clear sewing standards, and appropriate material selection.
6. Accessory Production & Inspection
Objective: Procure and inspect accessories that the main factory cannot produce, such as stickers and buckles, before assembly.
7. Final Assembly
Objective: Assemble main parts and accessories to produce the finished leather box.
Key Points: Address the strong odor from glue and thinner used in assembly by adding scents to reduce the smell.
8. Finished Product Inspection
Objective: Conduct sample inspections to ensure product quality.
Key Points: Isolate any problematic batch to avoid delays in delivery.
9. Finished Product Testing
Tests Include: Friction, high and low temperature, color difference, zipper durability, salt spray test, transportation test.
Equipment & Production Capacity
R&D Department: Design, engineering, and development.
Equipment: 2 laser cutting machines, 1 V-groove machine, 1 cutting machine, 2 punch presses.
Staff: 2 senior engineers, 4 CAD draftsmen, 2 mold makers, 2 BOM material calculators, 2 graphic designers, 25 sample makers.
Power Workshop: Cutting raw materials.
Equipment: 10 die-cutting machines, 2 paper cutters, 2 punch presses.
Injection Molding Workshop:
Equipment: 13 injection molding machines.
Staff: 1 senior 3D mold design engineer.
Daily Capacity: 160,000 units.
Brand Workshop: Producing high-security products.
Equipment: 7 sewing machines, 3 assembly lines.
Staff: 73 employees.
Daily Capacity: 10,000 units.
Production Workshop:
Equipment: 20 pneumatic machines, 20 gluing machines, 2 UV sterilization production lines.
Production Lines: 14.
Staff: 550 employees.
Daily Capacity: 30,000 to 80,000 units.
Quality Control Department: Inspection at four stages: IQC, IPQC, FOC, OQC.
Equipment: 2 temperature and humidity test chambers, 1 vibration tester, 1 electronic colorimeter, 1 zipper tester, 1 friction tester, 1 salt spray tester.
Staff: 48 quality inspectors.
Warehouse:
Finished Product Warehouse: 1800㎡.
Raw Material Warehouse: 600㎡.
Conclusion
Leather boxes are an excellent choice for packaging, offering durability, versatility, and a unique aesthetic. If you need more information or wish to see various leather box designs, please contact us.
