Corrugated cardboard is not the same as traditional cardboard boxes. Mixing them up can lead to damaged products, unhappy customers, and lost sales.<\/p>\n\n\n\n
But what exactly are corrugated boxes, and why are they used in over 95% of product shipments across North America? In this article, we\u2019ll break down what they are, how they\u2019re made, and why they\u2019re a smart packaging solution for nearly every industry.<\/p>\n\n\n\n
\nCorrugated 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.<\/p>\n<\/blockquote>\n\n\n\n
The fluted layer\u2014a wave-shaped piece of paper placed between flat linerboards\u2014is 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.<\/p>\n\n\n\n
Because of their structure, these shipping boxes are:<\/p>\n\n\n\n
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- Lightweight, reducing shipping costs<\/li>\n\n\n\n
- Strong and resistant to crushing or tearing<\/li>\n\n\n\n
- Available in many flute profiles and thicknesses for different needs<\/li>\n<\/ul>\n\n\n\n
This type of packaging solution is commonly used in various industries that require high performance and protection in their shipping methods.<\/p>\n\n\n\n
How are Corrugated Boxes made<\/h3>\n\n\n\n
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\u2019s certificate printed on the bottom, verifying the material\u2019s specifications like bursting strength and ECT.<\/p>\n\n\n\n
At the core of every corrugated box is the fluted layer\u2014a piece of paper that\u2019s been shaped into an arch-like wave and sandwiched between two flat sheets known as linerboards.<\/p>\n\n\n\n
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:<\/p>\n\n\n\n
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- A-flute<\/strong>: Excellent for cushioning and stacking strength<\/li>\n\n\n\n
- B-flute<\/strong>: Great for printing and space efficiency<\/li>\n\n\n\n
- C-flute<\/strong>: A balance between A and B<\/li>\n\n\n\n
- E-flute<\/strong> and F-flute<\/strong>: Used for retail and custom packaging solutions<\/li>\n<\/ul>\n\n\n\n
Once the desired flute type<\/strong> is selected, it\u2019s glued between two linerboards using heat and pressure. The result is a durable corrugated <\/strong>material that can be shaped, folded, printed, and cut to suit any industry requirement.<\/p>\n\n\n\n
In high-volume applications, this process is automated to ensure consistency, precision, and reduced manufacturing costs.<\/p>\n\n\n\n
Types of corrugated boxes<\/h2>\n\n\n\n
Corrugated boxes<\/a><\/strong> are categorized based on the number of fluted layers and the type of flute profiles <\/strong>used. These variations affect their strength, durability, and intended applications.<\/p>\n\n\n\n
There are four main types of corrugated cardboard boxes:<\/p>\n\n\n\n
1. Single face board<\/h3>\n\n\n\n
A single face<\/strong> board has one linerboard attached to a fluted <\/strong>layer, with the other side exposed. <\/p>\n\n\n\n
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- Lightweight and flexible<\/li>\n\n\n\n
- Used as a protective wrapping layer<\/li>\n\n\n\n
- Not suitable for standalone shipping<\/li>\n<\/ul>\n\n\n\n
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.<\/p>\n\n\n\n
2. Single wall board<\/h3>\n\n\n\n
Single wall boards<\/strong> are the most common style of corrugated cardboard and they are considered the standard. This is the most commonly used corrugated box construction.<\/p>\n\n\n\n
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- One fluted layer between two linerboards<\/li>\n\n\n\n
- Ideal for shipping boxes and retail packaging<\/li>\n\n\n\n
- Compatible with most printing techniques<\/li>\n<\/ul>\n\n\n\n
As previously described, they consist of a fluted layer between 2 liners. These are especially used for shipping cartons.<\/p>\n\n\n\n
3. Double wall<\/h3>\n\n\n\n
Double wall<\/strong> 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.<\/p>\n\n\n\n
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- Provides enhanced compression strength<\/li>\n\n\n\n
- Common flute combinations: BC flute, EB flute<\/li>\n\n\n\n
- Suitable for heavy-duty packaging<\/li>\n<\/ul>\n\n\n\n
4. Triple wall<\/h3>\n\n\n\n
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<\/a> or combined with other materials. For example, our hybrid corrugated box<\/a> combines the natural resistance of wood and lightness of corrugated board to make it the ideal box for heavy items while being cost-efficient.<\/p>\n\n\n\n
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.<\/p>\n\n\n\n
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.<\/p>\n\n\n\n
By selecting the appropriate flute profile and wall composition, businesses can optimize for strength, cushioning, and shipping cost-efficiency.<\/p>\n\n\n\n
Benefits of corrugated cardboard packaging<\/h2>\n\n\n\n