Corrugated Boxes: Production, Types, Uses and Advantages

What are corrugated boxes? If you are not familiar with the world’s greatest packaging solution, you are in the right place. Let us educate you on the subject of corrugated boxes, as well as the various applications for and types of corrugated packaging.

What is a Corrugated Box?

A corrugated box is a single-use container that consists of several layers, depending on your level of service, you can have a single wall and double wall. The middle layer is fluted or wavy, which typically provides cushioning and reinforcement for the heavier contents.

In addition, it adds the strength and crush resistance that isn’t always present in cardboard. At scale, the corrugated box was invented over two hundred years ago and the converging of the flutes from the cardboard into the corrugation in the middle of the box happened near the middle of the first industrial revolution.

Since the inception of the corrugated box, it has progressively replaced the cardboard box as the most common use for shipping containers and is utilized in every stage of logistics and the handling of materials.

Important Element For Making Corrugated Box

A corrugated box has three different wall configurations: single-wall, double-wall, or triple-wall.

Wall Configurations

• Single Wall – This is the least complicated corrugated wall designation, consisting of a single outer layer, and a single inner layer, with the fluting in between.
• Double Wall – The double wall indicated the addition of a fluting layer, allowing that box to handle heavier and larger items.
• Triple Wall – This is a triple wall corrugated box, meaning that it has three flutes, each layer with different sized flutes for stability. Including the 3 layers maximizes cushioning and compression strength, as needed.

Corrugated Flutes

Corrugated boxes typically use one of five standard fluted types, A, B, C, E, and F. Even though these are common known types, designers and manufacturers can modify the standard fluted designs to accommodate needed, including either a combination of standard types or a completely unique design.

• A – is the original flute type, with 36 flutes per foot, and is used primarily for double wall applications or thick corrugated padding.
• B – has the second biggest arch size with 49 flutes to the foot, and also has stacking strength and resistance to crush.
• C – the most common flute size with 41 flutes to the foot, used for average cushioning, stacking strength and printing properties.
• E – the second common flute, used for its environmental properties with 90 flutes to the foot.
• F – has small, tighter flutes, and also environmentally friendly with 128 flutes to the foot.

In addition to the five standard flute types there are also specialty flutes which are combination or fall in between standard, including D flutes. Specialty flutes are also EE, EF, and BC.

Specialty flutes are regularly seen in double-wall profiles. There are also flute sizes which are rarely seen, like N and O. N and O are used commonly in specialty products and are very small, being a little under half a millimeter in height.

Mullen Test (Burst Strength)

Burst strength of the corrugated box material refers to an amount of force the material is able to withstand before rupturing, cracking, or falling apart.  The Mullen Test, developed over 130 years ago, applies force to the face of the corrugated material until the material ruptures. 

The results of the Mullen Test are provided in pounds, which is the amount of force per square inch the material can withstand. 

For example, if a box was rated at 200# the box can withstand a force of 200 pounds (90kg) per square inch.  The Mullen Test specifically indicates how much pressure must be exerted to burst through the paper on a corrugated box.

The Mullen Test demonstrates how well a box will hold up to handling in shipping from assembly operations through distribution, so it indicates the expected handling, not the burst strength of the material.

It provides an indication of the carton’s puncture and damage resistance as it progresses through the handling process. The Mullen Test will not provide information on the contribution of the flute medium to the carton’s strength.

The flute medium is important because it accounts for roughly 50% of a carton’s stacking strength, yet the fluted medium is not part of the Mullen burst strength test. This is where the Edge Crush Test (ECT) is useful.

Edge Crush Test (ECT)

The Edge Crush Test (ECT) is a measure of the vertical compression strength of a corrugated box; basically, it is an indication of how well a carton will hold up when stacked, either during shipment or on a pallet.

ECT tests are practical measures of a carton’s ability to withstand substantial handling while maintaining its integrity. ECT is a “performance-based” material property test, meaning it evaluates performance as a box in compression without having tested much of the ECT for component materials.

There are many elements that can affect the ECT of a carton, including relative humidity, the length of time a carton is stacked, the amount of crush the carton receives through production machinery, and the stacking pattern. For example, an ECT of 55 can resist 55 pounds (25 kg) of pressure before it collapses.

Basis Weight

The basis weight refers to the weight of a cardboard sheet, prior to being converted to boxes. All basis weights are referenced in pounds and refer to the weight of a ream of paper, which is usually the weight of 500 sheets.

Paper is made in differing sizes and different widths, so the basis weight varies somewhat. Basis Weight is calculated by measuring and weighing a sample of paper.

Paper Weight

Paper Weight The weight of cardboard is characterized by the thickness of the cardboard paper. Land based weight is measured in pounds (lbs) and the paper weight of the paper used to produce corrugated sheets typically ranges from 26 lbs to 42 lbs (11.8 kg to 19 kg).

Coatings

There are several coatings and finishes that are applied to corrugated boxes during the production of boxes to be more durable and visually attractive. The main types of coatings for surfaces are aqueous coatings and UV coatings.

• Aqueous: Aqueous is a fast drying, clear coating that protects the surface of a box. Aqueous can be high gloss or matt and protects against wear and dirt.
• Ultraviolet (UV): Ultraviolet is cured by ultraviolet light and resists scratches and scuffs. Ultraviolet is more expensive than aqueous coating, but it lasts longer and is stronger.

How Corrugated Boxes are Made

The process of making a corrugated box may seem simple. Although it seems simple, many important factors must be taken into consideration before starting production.

As with all manufactured and shipped products, corrugated boxes are carefully designed and engineered to dictate how much each box can hold, its strength, and durability.

Producing Corrugated Board

Making Corrugated Board The machine that makes the corrugated board used in boxes is called a corrugator. The main parts of corrugated board are the liners, which are the outside flat layers made from different paper grades.

The middle layer, the flute, is made from short fibers, usually from hardwood trees, and the liners are made from longer fibers from softwood trees.

The main process makes use of giant rolls of paper and a single facer to create the flutes. The paper is treated with steam and heated to approximately 338°F (170°C).

Adhhesive is applied to the tops of the flutes to bond the fluted paper to a liner sheet. The two layers are pressed flat with rollers, which form a single-faced web.

The single-faced web leaves the single facer and enters the double glue unit and double backer. To form double-wall corrugated paper, two single-faced webs and the liner all enter the double glue unit.

In the double glue unit, adhesive is applied on the exposed tips of the flutes to bond the outer liner. During this stage, the liner and fluted webs will be heated to specific temperatures to properly set the glue and form a solid connection.

Next, the corrugated board enters the dryer, is scored, and is cut to its proper dimensions.

Various sizes of corrugated board are stacked together and assembled for the box imprinting and manufacturing process. Depending on the dimensions of the box, they are printed with a variety of logos, designs, and colors.

Finalizing Corrugated Boxes

The corrugated boards are scored, printed, and cut, and then continue through a trimmer to create flaps and handles. These machines can produce as many as 90 boxes a minute.

After trimming, the corrugated boards enter a folding machine, where the boxes are folded along their scored lines and adhesive is then applied in areas that need to be sealed, and are then assembled into boxes.

Types Of Corrugated Boxes

Corrugated boxes are adaptable and can be designed to meet every shipping requirement, which creates countless configurations in shapes, sizes, thicknesses, and styles. This includes custom boxes that meet the particular needs of customers.

Even though there are so many box types, they all have some base features that more advanced shapes are built off. An average corrugated box has the basic features of having a lid, top, sides, bottom, and inner containment.

These five basic features make up all box configurations, and variation in these elements can create the different types of boxes.

In general, it is assumed that all corrugated boxes are built to be strong, durable, and long lasting, as they are constructed and engineered to fulfill specific needs that fit within specified conditions.

Slotted Boxes

A slotted box is made with corrugated fiberboard that has been pre-scored and slotted into a foldable corrugated container.

Of all types of boxes, slotted boxes are the most common in shipping, and everything that is shipped and stored, from products to chemicals to parts, the slotted box is the most common type of bo,x and it can be used for something close to everything.

Slotted boxes refer to several types of boxes that have different configurations, characteristics, and uses (noted below).

• Regular: Flaps are the same length, and the two blade flaps are half the width of the container. When folded, the outer flaps meet in the center of the box.
• Half: The half-slotted corrugated box is like the regular box, but it lacks one full set of flaps to make the top.
• Overlap: The flaps are equal length, and the outer flaps overlap. The overlapping flaps are fastened to complete the box. A box with an overlap design is longer than it is wide.
• Full Overlap: One longer box provides the same length, with outer flaps overlapping at the top and bottom for more strength for heavier items.
• Center: In a center slotted corrugated box, the inner flaps are shorter than the outer flaps, meeting at the center when folded.
• Divider: The divider container is like the other slotted container box, but in the center of the interior section, it has a pre-glued divider.

Telescope Boxes

Telescope boxes are designed and named based on the style of construction, where each box is made of two separate, foldable parts: the body and the cover.

The body is the main part of the box that holds the item, and the cover is the lid that covers the body. The cover fits over the body when constructed, and the two sections overlap as they stack and create a sound container for transport and storage.

Rigid Boxes

A rigid box made either with corrugated or cardboard materials, consists of two end panels and the central body, which is constructed differently than standard way, by folding the end panels into place at the ends of the box.

The body piece folds together, with the end panel sections positioned to complete the construction of the box. The rigidity of the box comes from how the box flaps or joints are positioned.

In the self-erecting style, a single piece of scored corrugated fiberboard is designed to rather readily fold into a slotted or telescope box and can be instantly folded into its final form with no assembly among steps.

Folder Boxes

Folder corrugated boxes are a hybrid of the self-erecting \rigid’ type. A folder corrugated box is also a single piece of corrugated fiberboard that has been scored so it can also be folded together. Types of folders include: 1. one piece. 2. five panel, and 3. tray.

A one piece folder has a flat base with flaps that can be folded to produce the sides & ends of the box, while the side flaps extensions create the top.

In the five panel version, the panels fold in one direction with the second and fourth, top and bottom, and the fifth as a side panel.

Trays are available as five panel tray and four panel tray. The five panel tray includes a top panel while the four panel tray does not.

Tucktop Auto Bottom Boxes

Tucktop corrugated boxes employ a box style designed for easy assembly. Tucktop boxes are pre-glued, start out flat, with the bottom tuck in the box body and the top flaps (tabs) extend out of the box.

To set up the box, just open the box sides that causes a bottom flattening meaning it is ready for loading. A tucktop box can be assembled very quickly by the user in one motion.

A variation of this is a tucktop snap lock bottom box. Unlike the tucktop the snap lock does not have a pre-glued bottom.

The bottom end is created by folding the four flaps together. The most important differences in these two types of boxes are the time it takes to set one up, and the cost.

Double Cover Corrugated Boxes

The body of a double cover corrugated box is rectangular or square tube shape and has corrugated telescoping covers which both sit flat until needed.

When it is time to put together the box, the covers are engaged independently into the same tube, and they open to slide in the covers.

Double cover boxes are also made as interlocking. The interlocking nature allows for a tighter assembly. In addition, the overall strength of the box is enhanced when made interlocking.

An interlocking double cover box is designed so that it can be used to ship heavy items (appliances, heavy equipment, and other heavy items).

Advantages of using corrugated boxes

After reviewing the numerous aspects of corrugated boxes, as they pertain to the strength of corrugated boxes as a shipping solution, their importance is evident. The most beneficial aspect of corrugated boxes is their strength and durability.

They have strength and durability, before and after being assembled, because while corrugated boxes are made from molded paperboard and adhesive, they are made to endure all types of environmental conditions, from constant rain to extreme heat.

It is this versatility that is primarily responsible for the important role that corrugated boxes serve in world shipping logistics.

Protectve against Outside Elements

Corrugated boxes are very effective in protecting items from moisture and bacteria. They also provide a very good cushioning cushion, and they can be fitted to a number of products.

These boxes make sure the item is secure even through transit, shipping, and handling. Alterations in corrugated protection, utilizing different thicknesses and different sizes will ensure you use extra protection when shipping delicate and fragile items.

Corrugated fluted media provides a superior lightweight protective media. Correctly using corrugated fiberboard provides protection from the elements and from any damage resulting from handling.

It is lighter, cheaper, and more easily recyclable than wood or plastic, providing better ecological and economic sustainability.

Customizable to Demands

Corrugated boxes come in standard sizes and shapes, but can also be customized to fit many specific needs. Customizations can include logos, and decoration on the sides, top, and bottom of the box.

Coatings, treatments, adhesives, and flame-retardant options can be utilized with many different style corrugated boxes. Corrugated boxes come in many sizes and can be folded in various shapes to ensure a good fit.

A well designed custom design will make products available to stand out. Shipping materials that reflect good design values will propel a company’s operational values, as well as its brand equity.

A unique and perfect designed corrugated box design will help build the strength and longevity of your brand.

Cost-Effective and Reusable

It is likely that corrugated boxes are more used in the world today due to how cheap they can be compared to other container types. There is no additional labor, no expensive tools that you have to rely on, and no special equipment.

After their first use, corrugated fiberboard can be recycled and reused again for a considerable reduction in waste.

Compatible with Branding

Companies are always looking for new ways too branding. Putting your brand name and logo onto corrugated boxes is a cheap way to do this.

Even the smallest company can look competitive with an easy customizable brand on their box provide advanced design. Custom branded corrugated boxes give customers a good impression and help create a professional image.

Biodegradable and Eco-Friendly

Corrugated boxes are easily recyclable and can be used for various applications. As we develop an environmentally conscious society, companies have taken an interest in protecting and conserving the world.

Since over 70% of all of the materials used to produce corrugated boxes can be recycled, these boxes play a big part in a company’s commitment to sustainability.

Corrugated boxes are made from environmentally safe glues and materials and meet all environmental guidelines.

Lightweight Materials

While shipping costs are a key component of all logistics departments, understanding that heavy shipping boxes can quickly increase shipping costs, corrugated boxes are a strong, lightweight option for shipping purposes.

Although lightweight, corrugated boxes are strong enough to easily protect a product while in transit.

Flexible Paper Types

There are different styles of corrugated fiberboard: single wall, double wall and triple wall, all of which can be manufactured from multiple types of paper, depending on the shipping situation.

This diversity means that all products accommodated through the use of either corrugated cardboard or boxes.

Economical and Custom Printing

Printing company graphics, logos and brand names on corrugated fiberboard is realistic and affordable. Budgeting for custom printed fiberboard is usually built into the cost of the fiberboard.

Custom printing is such an important aspect of branding for any company, it should always be built into your budget, so there are no additional expenses for branded advertising.

Corrugated boxes are the perfect vehicle for combining marketing with logistics, and the flute protection and flat side provide an easy-to-use display area.

Using corrugated boxes allows companies to enhance their logistics process in a more personalized, creative manner.

A unique box design can portray a business culture and personality in a way that makes it stand out from its competitors, enhancing the customer’s view of their market position.

Product Safety

Corrugated cartons provide a physical barrier for products traveling substantial distances. During this travel, a product is subjected to many environmental conditions.

The flutes and walls of a corrugated box provide cushioning when faced with environmental changes as well as rough handing during shipping.

The barrier provided by the corrugated box also provides extra protection to products from shocks, abrasions, vibrations as well as rough handling while in-transit.

Additionally to physically safeguarding products, corrugated cartons form a barrier to protect fragile products like perfumes and chemicals from possible contaminants, including dust and bacteria.

The protection that the fiber-based structure of corrugated cartons provides acts as a shell to provide protection when products are delivered.

Sustainability

Today’s business practice has a great emphasis on sustainability with a focus on reducing waste and operating sustainably with a supply chain.

Corrugated cartons help support sustainability, as they are recyclable and repurposing tools at the end of their lifecycle. This is sustainable and eliminates diminishing returns while ensuring the supply of corrugated will always be there.

Meets Global Recycled Standard (GRS)

The Global Recycled Standard (GRS) is an industry-wide standard globally recognized for addressing both climate and biodiversity dilemmas.

GRS provides a certification for a wide-reaching array of products that incorporate recyclable content, even outside of the textile industry.

GRS-certified organizations make their claims, as GRS-certified products meet social, environmental, and chemical criteria.

Organizations become GRS certified based on multiple criteria, including:

• The Reclaimed Material Declaration Form guarantees that materials that were designated for landfills will be reclaimed.
• The Transaction Certificate recognizes the transfer of ownership and recognizes including the requirement for pre- and post-consumer recycled content of materials.

Application for corrugated boxes

Generally accepted as the standard container for shipping, the corrugated box is one of the most common forms of transportation for manufacturers when transporting a product.

The corrugated box can be tailored to fit almost any need. This is one of the reasons it is considered the most versatile solution for shipping.

The boxes are recognized for their durability and strength, as well as their ability to protect fragile items during transit. The versatility of corrugated boxes allows them to be customized for many shipping needs.

Another important aspect of corrugated boxes is the ability to print on them. Many companies print paper logos on the boxes as a way to improve their branding and recognition as a company.

A clearly identifiable and nicely designed logo on boxes can have a positive impact on branding and recognition. Branding using boxes can be a cost-effective method to begin making logos recognizable.

Food Industry

A glue made of water and starch are used to affix the flutes and liners when producing corrugated boxes. This type of glue affords protection against injecting contaminants in fresh produce such as fruit and vegetables.

Corrugated boxes are also recognized for their various benefits for food shipping. Safety and resistance to bacterial growth are the two prominent concerns to potential drawback with corrugated boxes.

Studies have demonstrated corrugated boxes in food shipping can maintain freshness in food for long periods of time.

Office Supply and Stationary

When shipping or storing office supplies that are primarily paper products, one of the largest concerns is the possibility of damage while being shipped and while sitting on shelves.

Corrugated boxes have been created to alleviate this problem by providing strength and cushioning to lessen the chances of damage while also ensuring that office products remain in good condition.

E-Commerce

In e-commerce, corrugated boxes are critical for maintaining an efficient, quick, and agile supply chain. In fact, corrugated box usage has increased over the past two years, taking a central role in e-commerce logistics.

The e-commerce sector faces a major challenge with shipping smaller amounts to a variety of locations. Corrugated boxes offer the security and protection needed by the e-commerce sector to meet their safety and reliability needs.

Textiles

The growth of online shopping has led to a substantial increase in the use of boxes for shipping textiles. Most industry has made large scale investment in packaging solutions to make sure deliveries are safe, reliable and arrive intact.

Because customer satisfaction is important for customer retention, corrugated boxes are critical to meeting customer expectations.

Research has shown that more than 50% of people surveyed would likely return to a company if their textile orders arrived packaged properly.

Corrugated boxes provide opportunities for textile producers to tailor their packaging to the product as well as their consumer, thus encouraging repeat purchases and customer loyalty.

Electronics

When shipping the electronics and electronic components, it is important to choose the right type of packaging due to the fragile nature of the goods being shipped. If not packaged correctly damage is easy to do.

Corrugated boxes are often accompanied by other packing materials for extra protection as the main concern is stress on the components when being handled where damage could occur in the circuit or loose connections.

The cushioning of the corrugated boxes offers some level of protection to make sure the electronic products arrive and operate well.

Healthcare

Not too different for the healthcare industry, the product will include some sort of closure or wrapping to protect the items from being fragile.

Consider medical instruments, if the package is not wrapping them with integrity than an instrument could be destroyed or be rendered useless through lack of packing integrity combined with rough handling.

There are shipping conditions to be met for medications to safely complete their intended purpose. The options for corrugated boxes allow health providers, pharmaceutical companies, etc. the ability to ship medications with the confidence their products and medications are adequately retained and protected in transit.

Batteries

Packaging and shipping materials for the battery industry has to follow strict safety guidelines and regulations. The fiberboard used to produce the two boxes that are formed for the given case comply with the industry standards for corrugated packaging.

In addition to the specialized liners, every shipping container has to be marked with appropriate handling instructions and information about the contents and their safe handling to comply with regulatory instructions.

Automotive

Packaging and shipping auto parts requires a lot of preparation since the sizes and shapes of each of the items are diverse. The last thing we want to do is to damage each item as it is packed in or being shipped in a box.

It is important to consider any individual parts the weight supports and the material and container box and packaging used for cushioning.

In general, the type of container will depend on the items, from a lug nut to a carburetor. Larger items will require box packaging with thicknesses sturdier for its handle. “Recommended Box Type” charts are often used from manufacturers and suppliers when choosing the type of box for auto parts.

Military

Packaging and shipping auto parts for military applications has particulars or Mil-Spec, unlike other industries, the military establishes the requirements for the packaging materials, production processes. The primary requirement for MIL-SPEC boxes is durability.

The corrugated boxes that are military grade should be manufactured and engineered to endure environmental conditions like high humidity, extreme temp changes, and moisture.

The combined of packing it along with the military shipping materials, ideally offer the highest level of protection for the sensitive, technical equipment while complying with the American Society for Testing and Materials (ASTM) standard D5118 and as with other packaging products.

Publishing

For publishing houses shipping books, documents, magazines, and printed materials all require consideration of weight. The concerns with high shipping volume samples of printed items when addressed on a single item from a distributor can be a hefty product to ship.

After the consideration of weight has been addressed, the second threat level is water as wet materials can create the most damaging occurrences for printed materials.

Corrugated boxes are shipped out fitted with protective coatings on the outer portion. It is advisable as a precaution to not box shipped without protecting the inner portion lined with plastic or other wrapping material afford their printed material another layer of protection against moisture.

A good solution would be to establish that each box be manufactured from triple-ply fiberboard like by offering their products with printed materials with protected boxes.