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Corrugated Packaging Solutions

Custom Brown Boxes optimized for Strength, Efficiency, and Savings.

THE EVOLUTION OF CORRUGATED SHIPPING BOXES

Corrugated boxes represent one of the most significant innovations in packaging history. These versatile containers consist of three layers: an inside liner, an outside liner, and a fluted corrugated sheet between them. This seemingly simple structure creates extraordinary strength and protection capabilities that have revolutionized the shipping industry.

The classic corrugated shipping box offers unparalleled advantages in the modern supply chain. Its structural integrity comes from the arch-shaped fluting pattern, which provides exceptional strength while maintaining a lightweight profile. This design enables boxes to withstand significant compression forces during stacking and protects contents from impact during transit.

THE POWER OF OUR IN-HOUSE CORRUGATOR

What sets StandFast apart is our advanced in-house corrugating facility. This isn’t just about manufacturing – it’s about complete control over quality and customization. Our corrugator allows us to:

  • Maintain consistent quality standards
  • Offer faster turnaround times
  • Provide competitive pricing
  • Create custom flute profiles
  • Adjust board grades on demand
  • Respond quickly to emergency orders

By managing the entire production process under one roof, we eliminate supply chain uncertainties and ensure your packaging meets the highest quality standards every time.

WHAT IS CORRUGATED PACKAGING?

Corrugated packaging, usually created by one or two flat linerboards and a fluted corrugated sheet, is widely utilized by the shipping and distribution industries. Since the fluted layer effectively retains vibratory motions and impacts during transit and contributes to the visual appearance, the corrugated material safeguards and aesthetically covers packaged goods. This packing style is widely used due to its durability and resistance to deterioration and, therefore, used to convey goods. Corrugated packaging products are also friendly to the environment because they can be recycled. It can be made in various styles and sizes and, being lightweight, can be easily transported, making it ideal for usage by various companies aiming at optimizing packaging materials.

INSIDE THE CORRUGATOR: HOW CORRUGATED BOARD IS MADE

A sophisticated machine called a corrugator joins several layers to form a corrugated board. This precise machinery attaches kraft paper to flat liner sheets by heating, shaping, and bonding it to produce the characteristic wavy middle layer or fluting. The corrugation process involves several key steps:

  • Conditioning the paper with steam and heat
  • Forming the flutes using precision rollers
  • Applying adhesive to bond the layers
  • Pressing and drying the combined layers
  • Cutting and scoring the finished board

Modern corrugators can produce different flute profiles, varying in height and frequency, to meet specific packaging requirements. Common profiles include:

A-flute: Offers maximum cushioning and stacking strength

B-flute: Provides excellent printing surfaces and compression resistance

C-flute: Balances cushioning with stack strength

E-flute: Perfect for smaller boxes requiring high-quality printing

F-flute: Ideal for small retail packaging

WHY CORRUGATED? THE SCIENCE BEHIND THE STRENGTH

The superiority of corrugated packaging products lies in their engineered design. The fluted middle layer creates thousands of arch-shaped supports, distributing weight and impact forces across the entire structure. This design principle explains why corrugated boxes can:

  • Support many times their own weight in stacking situations
  • Absorb impact shock during handling and transit
  • Maintain structural integrity in varying environmental conditions
  • Provide excellent insulation properties
  • Offer superior product protection with minimal material use

THE CREATIVE POTENTIAL OF CORRUGATED PACKAGING SOLUTIONS

Beyond its practical applications, corrugated material offers remarkable creative possibilities. The natural properties of the corrugated board make it ideal for innovative corrugated packaging in terms of:

Structural Design:

  • Complex folding patterns
  • Self-locking mechanisms
  • Multi-compartment configurations
  • Innovative display solutions
  • Custom protective inserts

Surface Enhancement:

  • High-quality graphic printing
  • Specialty coatings
  • Texture variations
  • Embossing and debossing
  • Lamination options

The nature of corrugated material allows for endless design possibilities, accommodating any size, shape, or strength requirement. These possibilities are also reflected in the custom corrugated boxes manufactured by our team at StandFast.

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ENVIRONMENTAL EXCELLENCE

Corrugated packaging stands as a model of environmental responsibility in the modern world:

Material Efficiency:

  • Made primarily from recycled paper fibres
  • Requires minimal virgin material input
  • Fully biodegradable and recyclable
  • Supports closed-loop manufacturing
  • Reduces transportation environmental impact due to lightweight nature

Sustainability Advantages:

  • Among the most recycled packaging materials globally
  • Requires less energy to produce than alternative materials
  • Creates minimal waste in manufacturing
  • Can be recycled multiple times without losing strength
  • Biodegrades naturally if it enters the environment

The future of corrugated packaging is going to be dynamic due to evolving environmental issues and the emergence of new technologies influencing the design, manufacturing and usage of packaging. While the options in packaging become more environmentally friendly, corrugated boxes are still ahead of almost all the other packaging types.

Our Expertise In Corrugated Packaging

In order to satisfy a variety of market expectations, StandFast’s corrugated packaging solutions include a broad spectrum of customized selections. 

E-Commerce Packaging

Pet Food Packaging

Food Packaging

Cosmetics Packaging

Frequently Asked Questions

What is corrugated packaging?

Corrugated packaging refers to boxes and containers made from corrugated board, which consists of a fluted corrugated sheet between two flat linerboards. This multi-layer construction provides strength and durability, making it ideal for shipping and storage. With multiple corrugators, StandFast Group produces our own corrugated board to control the quality of the material.

What are the different types of corrugated board?

  • Single-wall: One layer of fluting between two linerboards.
  • Double-wall: Two layers of fluting, three linerboards, providing extra strength.
  • Triple-wall: Three layers of fluting, four linerboards, used for heavy-duty packaging.

What are the benefits of using corrugated packaging?

  • Durability and strength: Protection for products during shipping.
  • Lightweight: Lower shipping costs relative to other options.
  • Recyclable and sustainable: Made predominantly from recycled materials and recyclable after use. StandFast Group provides 100% recycled paper as an option.
  • Customizable: Easily produced to specific product needs and brand marketing requirements.

How do I choose the right corrugated packaging for my product?

StandFast Group will work with you to develop the right choice for your packaging, while considering the following factors:

  • Product size and weight: Heavier products may require double or triple-wall boxes.
  • Shipping conditions: Fragile items may need additional padding or inserts.
  • Environmental impact: Choose recyclable or recycled materials.
  • Cost: Balance durability and brand marketing objectives with cost-effectiveness.

Can corrugated packaging be customized?

Yes, corrugated packaging can be customized in terms of size, design, printing, and additional features such as dividers, inserts and handles. Corrugated packaging can be designed for a specific purpose such as e-commerce or retail ready application. Corrugated board can be produced with specific paper combinations to suit your needs.

Beyond the standard brown box, StandFast Group can provide graphic corrugated packaging with branding, product information, and other graphics using various printing techniques like direct and pre-print flexography, digital printing, and lithography.

  • Custom design
  • Print options
  • Material combinations

How is corrugated cardboard made?

Corrugated cardboard is made by bonding fluted sheets of paper (the inner corrugation) with flat outer linerboards. 

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