When it comes to corrugated packaging, individuals often mistakenly consider cardboard as the only type of packaging material. However, there is more to it than that. Cardboard is one type of material, and corrugated cardboard is another. Both materials are often confused with one another but serve different purposes depending on the product.
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In this post, we will explore the differences between cardboard and corrugated cardboard, go in-depth into the various aspects of corrugated material, look into quality control, and discuss the benefits and uses of such material. By the end of this article, we hope to give you a better understanding of corrugated boards so you can make the best decision for your products packaging!
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A corrugated box is a container made from sheets of packaging material known as corrugated cardboard. Due to its strength and durability, corrugated boxes are widely used for shipping large or heavy products. In fact, 95% of all shipped products in North America use corrugated material!
Corrugated cardboard, also known as corrugated fiberboard or corrugated cartons, typically consists of three layers of kraft paper: two outer layers of flat linerboard and an inner layer of fluted (wavy) medium. For example, pizza boxes are commonly made from corrugated cardboard.
In some cases, additional layers can be added for extra protection, which we will discuss in more detail later.
Now that you know what corrugated packaging is and how common it is in shipping, you may wonder what the difference is between corrugated and cardboard. Weve mentioned briefly that corrugated cardboard differs from cardboard, but let us unpack this topic further.
Corrugated CardboardCardboard is generally made of paper stock or heavy paper pulp. Its typically used in folded cartons for smaller products but can also be used as structural support inside a box to keep its shape during transit. However, cardboard by itself is not very protective.
Corrugated, on the other hand, is different. It has three fiberboard layers, offering increased durability, protection, and versatility. This material resist bending and is among the best options whether your company is shipping large packages or sending a few products. Still unsure of the difference? Check out the chart below for a comparison!
With a better understanding of corrugated materials, choosing the most commonly used outside liner for manufacturing corrugated boxes should be less daunting.
But speaking of flute paper, now is a good segue into the different flute grades available, too!
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Corrugated flute provides cushioning, strength, and compression-resistant qualities to your package depending on the different flute grades, allowing for even more customization. But before we examine each flute profiles in detail, look at our corrugated flute chart for a quick visual comparison:
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Now that weve covered the different types of liners and flute grades, its time to look at combined board! Fluting and liners can be combined in different layers to create a variety of flute structures that have different thicknesses.
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Examining a little further with double and triple walls, different combinations of flute grades are possible with these options. Some industry standard combinations include:
With everything from construction to thickness covered, the corrugated box styles is the last topic to cover before moving on to quality control. By combining layers, customizing flute grades, or adding interior padding, corrigated boxes can fit any packaging need.
Custom corrugated boxes meet any specific requirement of the user. Some common types of corrugated boxes include:
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To view more box styles , visit PakFactorys corrugated box catalog.
With the sheer amount of design and customization options available at your fingertips, there might be many questions about protection. Corrogated boxes are subject to stress and impact during packing, shipping, and storage, so there needs to be ways to test your custom packages strength.
Some standard tests include the Edge Crush, Flat Crush, and the Burst Test.
All of these tests ensure the quality of custom corrugated packaging so your products have the highest level of safety they need to reach their final destination.
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After customization and thorough testing, its time to learn about the Box Makers Certificate (BMC). The BMC provides quick specifications about the box and comes in two versions: the ECT-rated BMC and the Mullen-rated BMC.
You will notice a few differences, but these box manufacturer certificate provide the same information:
If youve been following along, you probably already know some of the benefits of corrugated packaging. Here are the main reasons why corrugated cardboard is popular:
Many industries benefit from using corrugated packaging, especially e-commerce. Depending on the size and shape of the packaging, shipping and mailing can be more manageable. However, there are still some drawbacks to using corrugated boxes.
These drawbacks may be disheartening for companies with lower budgets. However, its important to weigh these drawbacks against the benefits it offers in terms of protection, recyclability, and versatility. Moreover, there are many ways to reduce costs and create affordable luxury packaging!
Source: PakFactory
Corrugated packaging is durable and customizable, providing creative freedom in corrugated box design to keep your product safe during transport. To learn more and start your project, contact our packaging specialists today!
Although most people confuse corrugated boxes with cardboard boxes, they are not the same. This might lead to a misunderstanding of the terminology. Cardboard is a heavy-duty paper stock that is widely used to make folding cartons and other items.
Folding carton boxes covering supermarket aisles are frequently made of cardboard. Consider a cereal box or a package of mac & cheese. This is hardly the kind of package you'd expect to make it through the shipping procedure. If you send one of these in the mail, it will almost certainly arrive in tatters.
The strength of a corrugated box, on the other hand, is paramount.
A liner and a medium make up corrugated boxes. These paper sheets are bonded together. They're usually three layers of fiberboard, but they might be substantially thicker.
The linerboard, or simply the liner, is the outer layer. Liners are flat materials that are normally found on the outside of the board, but can sometimes be found on the interior, as in the case of a double or triple wall.
The flute, which is a wavy layer in the center, is the medium. Corrugated packing boxes' strength comes from this inner player, which is why they're so popular for transport and storage.
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Kraft and test paper are the two most common types of paper used in corrugated boxes. The interior liner of the box is usually made of test paper, while the exterior liner is made of kraft paper.
Kraft paper is pricier than test paper, but it is of superior quality. Kraft paper is created from 70-80% virgin chemical pulp fiber and is made from softwood trees such as Pine, Spruce, and Fir. It's available in a variety of colors and textures, including brown, white, speckled, totally bleached, and birch-faced.
Kraft paper also has a smoother texture, making it easier to print on. It's also more water-resistant, which means the contents are better protected. It's also more durable than test paper due to its increased rip and burst resistance.
The Flute is C-Shaped curls in between to the two substrates, also called "corrugation". It is used to strengthen or reinforce the walls of your packaging. They look like wavy c-shaped lines that are glued to a paperboard. Fluting in the box gives your packaging strength and helps withstand any damage.
The flute size influences the thickness of the box walls and the stacking strength of the box. Flutes are identified by a letter that indicates their size. They're counted by their thickness and the number of flutes per linear foot.
The most popular flute sizes are:
At 1/4" thick, the A-Flute (33 flutes per linear foot) is the biggest flute. Because of its thickness, it provides a lot of protection and is a fantastic choice for fragile things.
B-Flute is 1/8" thick and has 47 flutes per linear foot. This is much thinner than A-flutes, but it has a surprising amount of strength. Its often used for counter displays or canned goods. Die-cut designs are common with this flute.
3/16" thick C-Flute (39 flutes per linear foot). Because it's the most popular option for shipping boxes, this is definitely the one you're most familiar with.
E-Flute (90 flutes per linear foot) is extremely thin, measuring only 1/16" thick. It lacks the strength of the larger flutes, although it does have some benefits. For folding carton boxes, it's occasionally used instead of paperboard. It's easy to store and use, and it prints well.
F-Flute (125 flutes per linear foot) is the narrowest of the flute classes at 1/32" thick. Because of its smooth surface, printed designs will appear sharp.
Even if you already know what flute size you want, you'll need to make some essential choices.
Corrugated packaging is available with a variety of wall thicknesses. Sometimes you just need a little extra protection for your items, and other times you need something more substantial.
Here are the are few types of walls you can choose from:
This is a single sheet of liner attached to one sheet of corrugated media that is normally offered in rolls. It provides extra padding for fragile things. If you're transporting something fragile like glass or electronics, you might use this as an extra layer of protection.
One sheet of corrugated medium is attached between two sheets of liner in a single-wall construction. It's the most prevalent and what most people think of when they think of a corrugated cardboard box.
This is more durable than single-wall, although it is less flexible due to the additional layer. This is sometimes used in certain POP Displays and packaging when additional protection or strength is needed. But it can potentially cause issues when printing, so the artwork must be designed to work specifically with its unique structure.
With three stacked corrugated sheets and four liner board facings, this is the strongest. It's commonly utilized for industrial parts or produce containers. It's extremely heavy-duty, and can be difficult to print certain artwork, just like double-wall. So if you choose triple-wall, it must be for a certain application.
Finding the perfect fit is also vital when choosing the right corrugated packing box for your products. Corrugated boxes are available in a variety of forms and sizes. You don't want to squeeze your belongings, but you also don't want them to float around. There are more packaging options, but these learning about the different styles is important.
Keep in mind that the internal dimensions of a box are stated as length x width x height when choosing a box size (L x W x H).
Here are some of the most popular box styles to pick from:
The most common is this one. Consider a standard shipment box. All of the flaps on this box are the same length, and when the box is closed, the two outer length flaps meet in the middle. The flaps will need to be taped together.
Because both sets of outside flaps fully overlap, making the box double-layered on top and bottom, this sort of box has increased strength.
You've probably seen one of these boxes if you've ever ordered a book or other media materials online. They're folded into a box after being creased and slotted. They're sleek but functional.
This box has a top and bottom that fit over each other, as the name implies. Its increased strength comes from the twin walls. Of course, these containers must be sealed in some way. For heavy-duty loads, corrugated boxes are usually sealed with packaging tape, tuck-in flaps, or strapping.
All of these options can be intimidating, but there are a variety of tools and services to help you get started on your search for the ideal box. If you'd like to learn more, you can talk to a representative at Bennett Packaging.
Of course, if you've gone to the work of figuring out what flute grade and wall type you'll need, you'll want some confidence that the box will perform as expected. And, in the end, that means safeguarding the contents of the box.
Everyone wants a box that will keep their belongings safe. No one wants to find their packaging crumpled and the items inside damaged.
Corrugated boxes go through a thorough testing process when it is needed. Depending on the retailer, or situation you are in, you might need to go through one yourself.
Here are four of the main tests conducted for corrugated boxes:
The Edge Crush Test determines the box's stacking strength, which can help you determine things like pallet shipment durability. ECT is a laboratory test procedure that involves compressing the board's edge between two plates. It's expressed in pounds per linear inch and is used to calculate a box's maximum compression force.
The force required to rupture or puncture corrugated cardboard is measured in the Bursting Test. This test determines how well a box will protect the contents of the box during shipping.
The Flat Crush Test assesses corrugated paperboard's resistance to flute crushing. Whether you pick digital or offset printing, this will help you calculate how much pressure you can safely apply to your box throughout the printing process.
Under defined settings, a Water Absorption Test determines how much water corrugated fiberboard absorbs over a period of time.
Finding the right corrugated box for your needs can be a daunting task. However, with the help of this guide, you should now have a better understanding of what to look for when ordering custom packaging. Finding a packaging manufacturer is an important step in your business, and we are here to help.
Always keep in mind the importance of protecting your belongings during transit, and remember that Bennett Packaging is here to help with all of your corrugated box needs. Contact us today for a custom quote on boxes.
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