Guide to Corrugated Boxes: Understanding Types, Design, and Costs
Many refer to corrugated boxes as cardboard boxes, while the two are technically different. A corrugated box is technically termed corrugated fiberboard boxes.
Although cardboard boxes are thicker and stiffer, and mainly used for holding things like playing cards and signs, corrugated boxes are sturdier and often used to hold goods through packaging and shipping. Cardboard is mostly used for different types of cardboard boxes called folding cartons but the corrugated fiberboard boxes provide better protection and strength during the transport of goods.
The Structure of Corrugated Box
A corrugated box is made up of two main parts which are linerboard and medium. The linerboard is the flat surface and medium is the wavy, fluted paper in between layers of linerboard. Both these are based on containerboard, and different types of linerboard and medium combination, therefore, impact the strength of the corrugated boxes.
Types of Corrugated Boxes
Understanding types of corrugated boxes will let you make the best choice for your packaging needs. The three most common types are listed below:
• Single Face: A medium attached to one linerboard with exposed flutes.
• Single Wall: A medium is inserted between two layers of linerboard so as to make the standard double-faced construction.
• Double Wall: Three layers of linerboard two mediums in between for strength.
• Triple Wall: Four liner boards consisting of three medium layers for ultimate strength.
Understanding Flute Profiles
Flute profiles describe the wavy pattern that is present inside corrugated boxes. The more the number of flutes, the bigger is the flute profile, and consequently, the higher is the cushioning ability along with compression strength. The smaller is the flute profile, the more suitable it is for the purposes of graphic design and retail packaging.
There are five basic corrugated box types. These have been classified based on flute profiles:
- A-flute: Stacking strength is excellent and has about 33 flutes per foot.
- B-flute: It is mainly used to hold canned products, and this type has approximately 47 flutes per foot.
- C-flute: Application in shipper cartons, about 39 flutes per foot.
- E-flute: Ideal for retail packaging, having around 90 flutes per foot.
- F-flute: For smaller packaging, 125 flutes per foot. It allows manufacturers to offer flexibility in corrugated box design by combining different flute profiles in a single board. Make sure that it has the suitable strength, cushioning, and thickness required for a specific application.
How to Measure Corrugated Boxes?
Always quote dimensions of corrugated boxes in a definite sequence. The sequence is: Length, Width, and Depth, in that particular sequence. The length represents the longest dimension of the box’s opening, its width represents the shorter dimension, while the depth represents the distance between the box’s opening and the opposite panel.
Due to the fluctuation of flute thickness, industry standard measures the inside of a corrugated box. For shipping or pallet configuration plans, the outside dimensions OD are always indicated (e.g., 12″ x 10″ x 8″ OD).
Common Types of Corrugated Boxes
Various corrugated boxes are made for particular purposes. Some of these are:
Slotted Boxes
- Regular Slotted Container(RCS): The most usual style, with all flaps being of the same length, such that when folded, the outer flaps meet at the centre point.
- Half Slotted Container(HCS): The RSC is almost similar to this, but one open side. Overlap Slotted Container: The outer flaps overlap for added strength and security.
- A full overlap slotted container(FOL): In which the outer flaps overlap and offer higher protection and cushioning to the contents of the box
- Centre special slotted container(CSSC): In which both the inner and outer flaps meet in the middle thereby reinforcing and supporting them.
Telescope Boxes
These boxes consist of a base and a lid that overlaps it. The lid can be longer than two-thirds the depth of the base or shorter, depending on the design. Some of the most popular designs include:
• Full Telescope Design Style (FTD): The lid overlaps more than two thirds the base.
• Design Style Container with Lid (DSC): A container with less than two-thirds of the lid covering the base.
Rigid (Bliss) boxes
These cartons consist of two identical end panels and a foldable body, providing stiff sides, a rigid bottom, and top. Once assembled, the cardboard boxes offer fantastic stiffness and strength.
Box Certifications
Most corrugated fibreboard boxes include a Box Maker’s Certificate, located at the bottom. They are indicating that they have passed industry standards. Such as the Mullen Burst Test or Edge Crush Test (ECT).
• Mullen Burst Test: It is the pressure that a box withstands before bursting.
• Edge Crush Test or ECT: This tests the stacking strength of a box, that is, what amount of weight it can carry before it collapses.
Difference Between Cardboard and Corrugated Shipping Boxes
Among the rest, one noticeable difference between cardboard boxes and corrugated shipping boxes is their structure and strength. Cardboard boxes are made from a single layer, hence more suitable for light goods like consumer goods or retail displays. Corrugated shipping boxes have more layers, making them stronger and more protective, and can better be used when shipping, storing, and transporting.
Cost To Make A Cardboard Box
The cost to make a cardboard box varies with the following factors:
- Materials: Increasing the quality of the cardboard or even layers of linerboard will increase the cost.
- Size: Larger boxes will require more materials and hence the more the box size, the more the price.
- Complexity of design: custom corrugated box design or printing may also increase prices. Small cardboard boxes usually cost between $0.50 and $1, but bigger more complex corrugated boxes are going to vary in price. This will be capitalised on if you order in bulk or you add features like coatings and printing.
How Much Does Packaging Cost?
This is the most frequently asked question: How Much Does Packaging Cost? So here is the answer. Packaging costs depend on a box type, material, and extra elements such as printing or custom design.
For the most basic corrugated boxes, packaging costs can be from 1 to 5 USD per box. When there is a need for custom sizes or other features like a logo or branding, then the costs increase according to what you want.
Summing up the above discussion:
This Guide to corrugated boxes gives you a rich understanding of types of corrugated boxes, structure, flute profiles, and designs. Need to know the difference between cardboard and corrugated shipping boxes or figure out the Cost to Make a Cardboard Box? Knowing your way around these factors helps you make the perfect decision for your packaging needs.
Whatever your need might be-selling little breakable parts in cardboard boxes, designing one-of-a-kind retail packaging, or anywhere in between-knowing what the right box looks like is key to getting the job done.
