Corrugated boxes entered the market in the mid-19th century. They were specially designed to pack and protect fragile items like glassware. The use of these boxes gradually spread to different industries as people realized their durability and convenience.
This blog discusses the making and application of corrugated boxes and how they align with sustainability.
What Are Corrugated Boxes?
Corrugated boxes are commonly seen in everyday delivery items or when shifting houses. They keep items safe and secure until they reach their designated place. They are created by combining three layers of specially designed sheets.
Primary Components of a Corrugated Box:
- Liners
Liners are the plain, coated or printed inner and outer layers on either side of the corrugated medium. - Fluting
Fluting is the wavy layer between the liners. It provides a cushioned effect, enabling the box to withstand external pressure or impact.
Even by combining these layers, corrugated boxes are lightweight yet strong, making them ideal to protect various products.
Making of Corrugated Boxes
Corrugated boxes are differentiated based on the layers of corrugated material combined to make their walls. Each type is manufactured in various shapes and sizes, with unique uses and functionalities.
- Single-Wall Corrugated Boxes
- Commonly used as a shipping and storage solution.
- Made of a single layer of corrugated medium sandwiched between two liners.
- The strength of these single-wall boxes is ideal for packaging medium-weight items.
- Double-Wall Corrugated Boxes
- Offers versatile use across industries.
- Made of two layers of corrugated material pressed between three layers of liners.
- The strength of these double-wall boxes is ideal for packaging fragile or heavy items.
- Triple-Wall Corrugated Boxes
- They offer a versatile use across industries.
- Made from three layers of fluting sandwiched between four layers of liners.
- Triple-wall boxes are the most durable and strongest, making them ideal to ship heavy equipment.
- Custom Boxes
- Used to highlight special offers and discounts.
- Custom-made according to the unique needs of businesses.
- Ideal for brands looking to boost their branding strategies.
Flute Profiles and Their Impact
Flutes can be differentiated based on their size. They determine the strength, flexibility and cushioning of corrugated boxes.
Types of Flute:
- A-Flute: They offer optimal cushioning and strength, making them ideal for fragile products.
- B-Flute: They are thin and inflexible, making them ideal for food packaging.
- C-Flute: They combine a cushioned layer, which is also stiff, making them ideal for shipping.
- E-Flute: They are thin and lightweight, ideal for printing and retail packaging.
- F-Flute: They are the thinnest among all flute types, used for small boxes or point-of-sale displays.
The choice of flute depends on whether you want strength, durability, printability or lightweight.
How Corrugated Boxes Are Made
The making of corrugated boxes involves several phases, including:
- Pulping
The paper used in the liners or flutes is made by pulping wood chips or recycled material. - Corrugating
The waves on the flute are created by pressing it through heated rollers. - Lamination
Different layers of corrugated material and liners are combined to make a single sheet. - Cutting and Shaping
The box is shaped according to particular dimensions by cutting, creasing and folding the corrugated board. - Printing and Finishing
The boxes are finished by printing logos, labels or designs.
Corrugated boxes manufactured using modern technology aim to reduce waste and make the boxes more reliable and environmentally friendly.
Applications of Corrugated Boxes
The applicability of corrugated boxes spans across industries, including:
- Shipping and Logistics
Corrugated boxes are ideal for shipping goods because they are durable, lightweight, and stackable. They ensure the products inside stay protected.
- Retail Packaging
Most retailers use customized corrugated boxes to display and protect the items inside them. Their printable exteriors make them a canvas for attractive branding.
- Food Packaging
Corrugated boxes are widely used in the food industry, storing everything from fresh farm picks to frozen items and beverages. They are often coated to make them moisture—and grease-resistant.
- Storage
For all storage needs, corrugated boxes help organize and protect items, offering a practical and cost-effective solution.
Tips for Choosing the Right Corrugated Box
Factors to consider when choosing corrugated boxes include:
- Weight and Fragility of Items
Choose a box that protects your product from external pressure and keeps it secure until it reaches its destination. - Size
The box you choose should be made to fit your item’s size, reducing the risk of movement when shipping. - Flute Type
Choose the flute type depending on the purpose of the box. - Customization Needs
If you are choosing corrugated boxes for branding or to highlight special features, look for customization options. - Environmental Impact
Consider choosing boxes that are recyclable or certified as sustainable.
How Corrugated Boxes Support Sustainability
Corrugated boxes are made from renewable materials, reducing dependence on unused raw materials that affect the environment. They can be re-made into corrugated sheets, minimizing wastes created by non-renewable sources.
Unlike synthetic packaging, corrugated packaging is biodegradable, minimizing its ecological footprint. Because of its lightweight and durable nature, it is easy to transport and consumes less fuel, reducing carbon emissions. Businesses using corrugated packaging benefit from customizing options for their branding efforts while maintaining the protection of items packed in them.
The versatile use and customization of corrugated packaging allow businesses to explore solutions that meet their customers’ unique needs. It helps reduce the need for surplus materials, supporting sustainability and maintaining a resource-efficient supply chain.
As a leading manufacturer of corrugated boxes, StandFast is committed to producing versatile, high-quality products across industries. Our use of advanced technology and renewable and recyclable materials to make customizable corrugated boxes makes us a premium choice for many businesses. The strong build of our packaging boxes ensures they are high-performing and align with modern business practices.
Conclusion
Corrugated boxes are an important part of retail strategies and sustainability. Understanding corrugated boxes’ structure, types, and applications can help you choose the right box for your business.
Whether you are a business looking to skyrocket your retail strategy or need durable and secure product packaging, StandFast offers various packaging options. Find the ideal packaging solution for your business today!