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Hexagonal and square footprints are both producible, and we have tooled round formats for specific gift applications. Facet count changes the internal cell layout, so each shape needs its own cell arrangement worked out at design stage rather than being a variation on the octagon mold.

On corner impacts, modestly, because eight corners share load that four would concentrate. On compression and stacking, the two are comparable, since load path in both cases runs through the internal cone structure rather than the outer wall. The shape is chosen for presentation, and the impact benefit is a secondary advantage rather than the reason to specify it.

 Higher than for a rectangular carton, because the tooling is more complex and the mold cost has to be recovered. Buyers testing the format should start on one of our existing octagon molds, which carries no tooling charge, and move to a bespoke facet count or dimension once the line is proven.

Generally not. Automatic lines are built around rectangular infeed geometry and expect a consistent leading edge. Octagon cartons are hand packed in almost every operation we supply. That fits their use case, since premium and gift volumes are usually low enough that hand packing is not a constraint.

They stack, but the pallet pattern is less efficient because octagons leave void space between units. The stack itself is stable, since each carton sits flat on the one below and the eight corners spread the load. What you lose is cube utilization, so allow for fewer units per pallet than a rectangular equivalent of the same cell count.