What is Corrugated Cardboard Packaging?

Corrugated cardboard is not the same as traditional cardboard boxes. Mixing them up can lead to damaged products, unhappy customers, and lost sales.

But what exactly are corrugated boxes, and why are they used in over 95% of product shipments across North America? In this article, we’ll break down what they are, how they’re made, and why they’re a smart packaging solution for nearly every industry.

What is a corrugated box?

Corrugated fiberboard, commonly known as corrugated cardboard, is the material used to create most shipping boxes. They are a type of corrugated packaging made from corrugated cardboard, a material known for its multi-layered construction. Unlike traditional cardboard boxes, which are usually made from a single sheet of thick paperboard, corrugated board boxes are built using at least three layers: an inside liner, a fluted layer, and an outside liner.

The fluted layer—a wave-shaped piece of paper placed between flat linerboards—is what gives these boxes their signature strength and durability. These corrugated materials create air pockets that improve compression strength and shock absorption, making them ideal for protecting items during transit or storage.

Because of their structure, these shipping boxes are:

• Lightweight, reducing shipping costs
• Strong and resistant to crushing or tearing
• Available in many flute profiles and thicknesses for different needs

This type of packaging solution is commonly used in various industries that require high performance and protection in their shipping methods.

How are Corrugated Boxes made

The production of corrugated shipping boxes involves a high-precision process that transforms raw paper into strong, protective packaging materials. Many corrugated boxes include a box maker’s certificate printed on the bottom, verifying the material’s specifications like bursting strength and ECT.

At the core of every corrugated box is the fluted layer—a piece of paper that’s been shaped into an arch-like wave and sandwiched between two flat sheets known as linerboards.

This central fluted structure is what provides cushioning, impact resistance, and increased compression strength. Depending on the specific need, different flute profiles are used during manufacturing. The most common include:

• A-flute: Excellent for cushioning and stacking strength
• B-flute: Great for printing and space efficiency
• C-flute: A balance between A and B
• E-flute and F-flute: Used for retail and custom packaging solutions

Once the desired flute type is selected, it’s glued between two linerboards using heat and pressure. The result is a durable corrugated material that can be shaped, folded, printed, and cut to suit any industry requirement.

In high-volume applications, this process is automated to ensure consistency, precision, and reduced manufacturing costs.

Types of corrugated boxes

Corrugated boxes are categorized based on the number of fluted layers and the type of flute profiles used. These variations affect their strength, durability, and intended applications.

There are four main types of corrugated cardboard boxes:

1. Single face board

A single face board has one linerboard attached to a fluted layer, with the other side exposed.

• Lightweight and flexible
• Used as a protective wrapping layer
• Not suitable for standalone shipping

They are the cheapest to produce but are also the least durable. They are therefore usually only used for an extra layer of protection on products that are already packaged.

2. Single wall board

Single wall boards are the most common style of corrugated cardboard and they are considered the standard. This is the most commonly used corrugated box construction.

• One fluted layer between two linerboards
• Ideal for shipping boxes and retail packaging
• Compatible with most printing techniques

As previously described, they consist of a fluted layer between 2 liners. These are especially used for shipping cartons.

3. Double wall

Double wall boards consist of two fluted layers and three linerboards in between and one on each end. The two fluted layers makes them more resistant so they can be stacked more easily. They are also commonly used for larger, heavier objects.

• Provides enhanced compression strength
• Common flute combinations: BC flute, EB flute
• Suitable for heavy-duty packaging

4. Triple wall

Finally, this type has three fluted layers with a liner between each and one on each end. It is therefore extremely sturdy and can be used to substitute wooden crates or combined with other materials. For example, our hybrid corrugated box combines the natural resistance of wood and lightness of corrugated board to make it the ideal box for heavy items while being cost-efficient.

This packaging material is traditionally used for shipping chemical containers due to their properties. Additionally, both double and triple wall boards can combine flute profiles due to their different layers. This helps adapt cushioning strength, compression strength and thickness.

Some corrugated shipping boxes combine different flute profiles to balance cushioning, compression strength, and thickness. The regular slotted container (RSC) is the most common corrugated box style, known for its efficient use of material and structural integrity.

By selecting the appropriate flute profile and wall composition, businesses can optimize for strength, cushioning, and shipping cost-efficiency.

Benefits of corrugated cardboard packaging

Over 95% of all consumer products in North America are shipped using corrugated boxes—and for good reason. These packaging solutions offer a powerful mix of performance, cost-efficiency, and sustainability.

Resilience

These shipping boxes are very sturdy and can be used to carry a wide range of weight. It is therefore suitable for nearly any item, including pharmaceutical supplies, bulk food or for everyday use in many different industries.

They are also tear-resistant and ideal for stacking in storage since they can support the weight of additional boxes. Corrugated boxes are sure to keep even the most fragile items protected during long-distance transport, shipping and handling conditions.

To ensure durability, corrugated packaging is often tested using the edge crush test (ECT), which measures the stacking strength of the material.

Eco-friendliness

Corrugated cardboard is a cornerstone of sustainable packaging, thanks to its recyclability and renewable material base.

Not only is the packaging itself recyclable, but it can also sometimes be made from recycled materials. Additionally, it can be folded back up and reused later on. This reduces energy and materials required to make new boxes. Their lightweight nature also reduces energy use during transportation, lowering carbon footprints.

Cost-efficiency

Corrugated packaging makes it very easy to reduce your packaging costs

These are some of the least expensive cartons available due to a minimal amount of labour and tools needed to manufacture them.

The fact that they are so lightweight also saves shipping costs making them cost effective.

Customizable

As seen above, they are offered in different board types. They can even have different coatings and treatments such as flame resistance, for example. Their properties will depend on your needs.

Printing options are also available. They actually have better graphics than many other materials which makes them effective for marketing and branding. Perhaps you would like to include your logo and other information about the products inside for true personalization. Corrugated packaging offers excellent branding opportunities with high-quality graphics.

Use Cases by Industry

The versatility of corrugated boxes makes them essential across a wide range of industries. Their unique combination of lightweight strength, custom packaging options, and cost-efficiency provides tailored solutions for both high-volume and specialized applications.

Retail & E-Commerce

• Protects products during shipping and returns
• Supports custom printing for brand identity and customer experience
• Often used with single wall or double wall construction

Manufacturing & Industrial Packaging

• Transports heavy parts, equipment, and machinery components
• Utilizes triple wall and BC flute combinations for maximum strength
• Replaces wooden crates with lighter, recyclable solutions

Food & Beverage

• Bulk packaging for produce, canned goods, and packaged foods
• Options for moisture-resistant liners
• Compatible with temperature-sensitive supply chains

Pharmaceutical & Healthcare

• Ships medical devices, vaccines, and diagnostics kits securely
• Requires flute profiles that offer excellent cushioning
• Often customized with labeling, tamper seals, and compliance info

Automotive & Electronics

• Protects sensitive electrical components and car parts
• Ideal for custom-sized corrugated packaging with internal dividers or foam inserts
• Combines durability and space efficiency

Each of these industries leverages corrugated cardboard boxes not only for protection but also for cost reduction, sustainability, and branding.

Corrugated Boxes vs Cardboard Boxes

Although they’re often used interchangeably, there’s a significant difference between corrugated boxes and cardboard boxes.

Cardboard Boxes or Carton Boxes

• Made from a single sheet of thick paperboard
• Commonly used for items like cereal boxes, folders, and lightweight retail packaging
• Cereal boxes are typical examples of cardboard boxes made from a single paperboard sheet, not designed for shipping.
• Not designed for shipping or handling heavy items 

Corrugated Boxes

• Constructed with a fluted layer between two linerboards
• Engineered for strength, cushioning, and compression resistance
• Widely used as shipping boxes in industries such as e-commerce, manufacturing, and pharma

Corrugated box style are simply more robust and versatile. They’re built to protect products in transit, endure stacking, and support high-quality printing and branding—features not available with basic cardboard packaging.

So while the term “cardboard” may be used informally, if you’re looking for reliable packaging solutions, corrugated boxes are the professional standard.

Creopack: your partner in custom packaging

At Creopack, we specialize in developing high-performance corrugated packaging solutions tailored to your specific industry and logistics needs. Whether you’re in e-commerce, manufacturing, pharmaceuticals, or retail, our team works with you to create custom packaging that delivers durability, efficiency, and style.

We design and manufacture a wide range of corrugated boxes, including:

• Single wall, double wall, and triple wall structures
• Options with moisture-resistant and flame-retardant coatings
• Fully custom-printed packaging for enhanced branding

With our expertise in corrugated materials and flute profiles, you’ll benefit from:

• Optimized protection during shipping
• Lower packaging costs
• A reduced environmental footprint through recyclable solutions

Whether you’re launching a new product or rethinking your entire supply chain, Creopack provides scalable, reliable, and sustainable corrugated packaging that helps your business succeed.

Contact us today for a free consultation and find out how our custom corrugated boxes can work for you.

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