A method of assembling a box comprising the steps of:
- (a) fabricating an irregular material pattern, said pattern comprising a first and second end panel, a third end panel flap foldably connected to a first and second side panel, which in turn are foldably connected to a first and second upper panel, a first and second bottom panel, and a first, second, third and fourth dust flap,
- and wherein said third end panel flap also comprises two angled ends,
- and further wherein said first, second, third and fourth dust flaps are rectangular,
- and further wherein said third end panel flap is a narrow strip of material,
- and further wherein said first upper panel comprises a spout further comprising a first, second, third, and fourth ply;
- (b) scoring said material pattern, wherein said scoring comprises first and second horizontal female scores, four vertical scores, said vertical scores being one of either male or female orientation, said scoring further defining box panels A, B and C,
- and further wherein a plurality of cuts in said box define four dust flaps,
- and further wherein said first and second horizontal scores and said vertical scores, together with said cuts, define two lower panels, two upper panels, and two side panels,
- and further wherein said scoring comprises a third and fourth horizontal female score defining said third ply and said fourth ply;
- (c) coating said material pattern with a water base coating;
- (d) applying a first glue pattern to said fourth ply;
- (e) applying a second glue pattern to said third ply;
- (f) applying a first side bottom panel glue pattern to an entire surface of a first bottom panel;
- (g) applying said first side bottom glue pattern to first sides of said third and fourth dust flaps;
- (h) turning said material pattern over to a second side;
- (i) applying a second side bottom panel glue pattern to an entire surface of a second bottom panel;
- (j) applying said second side bottom glue pattern to second sides of said third and fourth dust flaps;
- (k) folding said box, wherein said box panels A and B become parallel to one another and perpendicular to panel C after being folded relative to two vertical scores,
- and further wherein said fourth ply is folded over said first ply,
- and further wherein said third ply is folded over said second ply,
- and further wherein to complete assembly, said third dust flap is folded up about a female score as are said first and second bottom panels, thereby permitting said third dust flap and all other dust flaps to fit snugly and quickly into said first and second female scores, and also thereby providing a waterproof and sift-proof box and facilitating significantly more rapid and accurate assembly;
- and
- (l) affixing a clear adhesive removable plastic label over said spout.