Corrugated boxes are an integral part of the packaging industry, known for their strength, versatility, and recyclability. Whether it’s for e-commerce shipping or packaging large appliances, corrugated boxes are often the go-to choice. Here’s your master guide to understanding and utilizing corrugated boxes effectively.

1: Corrugated Box Basics

A corrugated box is made from corrugated paperboard that contains rows of air columns. These columns make the paper stronger than average cardboard, offering resilience, sturdiness, and lightweight protection, ideal for shipping and packaging heavy items.

2: Corrugated Box Styles

Corrugated boxes come in many styles, each with unique functions and benefits. Among these are the Regular Slotted Container (RSC), Full Overlap (FOL), and Half Slotted Container (HSC). Custom-designed boxes are also available to meet specific needs.

3: Types of Corrugated Cardboard

Corrugated cardboard comes in different types, such as single-face, single-wall, double-wall, and triple-wall, each offering varying degrees of protection. The choice depends on the weight of the product and the level of protection needed.

Corrugated flute is similar to liner boards save for the construction.

Corrugated flute provides cushioning, strength, and compression-resistant qualities to your package depending on the different grades, allowing for even more customization with your packaging. But before we examine each flute grade in detail, look at our corrugated flute chart for a quick visual comparison:

A-Flute – 1/4” is the first type of corrugated flute. This flute grade has the highest protection and cushion qualities. It is very good at handling compression and stacking and is often used for packaging fragile items.

B-Flute – 1/8”. This flute appears much thinner than others but is still quite strong, with excellent puncture and crush resistance. B-flute has outstanding all-around performance for various packaging or as additional material for padding and dividing. It even has a flatter surface for higher-quality printing and easy die-cutting. 

C-Flute – 3/16” is flexible and one of the corrugated boxes’ most versatile flute grades. It has average crush resistance, stacking strength, and printing properties. You have likely seen C-Flute used for shipping boxes but also for packaging glass, dairy, and furniture products.

E-Flute – 1/16” is not typically used for shipping. E-flute thickness is on the thinner side of flute grades, so it is often used as an alternative for paperboard folding cartons. However, you may still use E-Flute for cosmetics, fragile glass, ceramics, and other small and delicate products. E-Flute has excellent compression strength, crush resistance, and a relatively flat surface for high-quality printing applications.

F-Flute – 1/32” has protective qualities similar to E-Flute but with an even smoother surface for high-quality printing. It is common for you to use F-Flute for clamshell packaging in the US fast-food industry, but in Europe, this grade of corrugated fluting is a standard option for specialty and retail packaging.

4.Corrugated Cardboard Thickness

Now that we’ve covered the different types of paper liners and flute grades, it’s time to look at thickness! Below is a summary of the standard thickness options available:

Liner Board – The ‘face’ of the fiberboard sheet. You glue the flute onto this board.

Single Face – Consists of one liner board with glued flute visible on one side.

Single Wall – The most common thickness. Two liner boards with fluted fiberboard glued in between.

Double Wall – Three sheets of liner board and two fluted fiberboards in between.

Triple Wall – Four sheets of liner board and three fluted fiberboards in between. This option can withstand heavier weights up to almost 300 lbs but is less flexible.

Examining a little further with double and triple walls, different combinations of flute grades are possible with these options. Some industry standard combinations include:

AC Flute – A mix of the two most protective corrugated grades. AC Flute is excellent if you need extra protection for harsh shipping and handling processes. 

BC Flute – An outstanding all-around performer, this combination provides high-level transit protection and is common for shipping boxes.

EB Flute – Provides superior transit strength and safety, while the outer E-Flute allows for an excellent, high-quality printing surface.

5: Customizing Corrugated Boxes

Corrugated boxes are highly customizable. They can be printed with logos or designs, made to measure for specific product sizes, or treated with water-resistant coatings.

6: Environmental Impact

Corrugated boxes are a sustainable packaging solution. They are made from a high percentage of recycled material and are widely recyclable.

Frequently Asked Questions:

1. How are corrugated boxes different from regular cardboard boxes?

Corrugated boxes use a specific kind of cardboard with air columns for added strength and cushioning, whereas regular cardboard does not have this feature.

2. Can I use corrugated boxes to ship heavy items?

Yes, corrugated boxes are ideal for shipping heavy items due to their strength and durability.

3. Can corrugated boxes be used to package food?

Yes, they can be used to package food. Some corrugated boxes even have a wax coating for added protection against moisture.

4. Are corrugated boxes more costly than other forms of packaging?

While pricing can depend on many factors, including size and customization requirements, generally, corrugated boxes are cost-effective due to their construction and material.

5. Can I print on corrugated boxes?

Yes, you can print on corrugated boxes—anything from simple logos to complex, full-color designs.
In conclusion, corrugated boxes offer a blend of strength, flexibility, and environmental friendliness unmatched by many other packaging solutions. Their widespread use in a variety of industries is a testament to their versatility and efficiency. Getting to know corrugated boxes better can help you make the most of them and optimize their benefits for your packaging needs.