When it comes to shipping, the first packaging type that comes to mind is often the corrugated box. These boxes are made from corrugated cardboard, which many people mistakenly refer to as just cardboard. However, there’s a difference between cardboard and corrugated cardboard. While they’re often thought of as the same, they serve different purposes depending on the nature of the product.
In this blog, we’ll briefly explain what a corrugated box is and how it differs from regular cardboard. Our goal is to help you better understand the materials so you can make an informed choice for your product packaging.
What Is A Corrugated Box?
A corrugated box is referred to as a shipping container made from corrugated cardboard material. This box is famous for its durability and strength, which is why it is widely used to ship heavy and large items. According to a survey, approximately 90% to 95% products get shipped in corrugated boxes.
Now that you know what a corrugated box is, let’s take a quick look at its material!
What Is A Corrugated Cardboard?
Corrugated cardboard is famous by many names, such as corrugated fiberboard or corrugated cartons. This material consists of two layers of paperboard with an inner layer of flute (wavy linerboard).
The layers can be modified for extra protection depending on the product’s weight and type.
Difference Between Corrugated & Cardboard
Now that you’ve got a good idea of what corrugated packaging is and how often it’s used for shipping, you might be thinking how’s it any different from regular cardboard?
We have discussed it above, but let us dive a bit deeper!
Cardboard is made of heavy pulp paper. This material is used for manufacturing folding cartons for smaller products that can support their structural support. However, cardboard is not very protective as compared to corrugated material.
On the other hand, corrugated material is very different from cardboard. As discussed above, it has three layers that help in increasing durability and protection. Thanks to its strong structure, this material resists bending and provides reliable protection for everything from bulk shipments to smaller product deliveries. Some of the examples of packaging made from corrugated material, such as pizza boxes, mailer boxes, and more.
| Feature | Cardboard Boxes | Corrugated Boxes |
| Set up | Required | Required |
| Sturdiness | Low | High |
| Product Safety | Yes, with the help of inserts. | High |
| Cost | Vary upon printing & finishing options | Vary upon printing & finishing options |
| Appeal | Vary upon printing & finishing options | Vary upon printing & finishing options |
| Recyclable | Yes | Yes |
Corrugation Process
The corrugation process is the manufacturing process to craft corrugated cardboard. It is a layered material with a wavy or corrugated structure. This structure is formed by a fluted medium layer between two liner materials using heat, pressure, and adhesives.
Linerboard Material Used For Corrugated Cardboard
Corrugated cardboard can be made with various linerboards. A linerboard is the material used as a flat linerboard in the corrugation process.
Below are the most famous linerboards for corrugated material:
Kraft Paper: A strong, brown liner made from 70–80% virgin chemical wood pulp. It offers excellent durability and is commonly used for heavy-duty packaging.
Cardboard: A thick paper material commonly used in folding cartons. It provides structure and protection for retail and consumer products.
Paperboard: A thinner, smoother liner often used for detailed printing. It’s ideal for retail packaging where visual appeal matters.
Flutes or Medium Used In Corrugated Material
A flute or medium is the material attached between two linerboards. There are various flutes available with different thickness levels. Each corrugated flute sizes gets used for its unique purposes:
Let’s take a quick look at it.
- A-Flute: It is the thickest type of corrugated flute, measuring about 1/4″ (0.25″) in thickness. It provides excellent cushioning and stacking strength, making it ideal for packaging fragile or heavy items. This flute type is commonly used in heavy-duty shipping boxes where maximum protection is required.
- B-Flute: It is thinner than A-Flute, with a thickness of approximately 1/8″ (0.125″). It offers good puncture resistance and a smoother surface for printing. B-Flute is commonly used in retail packaging and die-cut boxes, especially for products like canned goods.
- C-Flute: This flute is one of the most widely used flutes, measuring around 5/32″ (0.156″) thick. It strikes a balance between strength and printability, making it suitable for shipping cartons and packaging glass or ceramic items. It’s often the go-to choice for standard corrugated boxes.
- E-Flute: It is much thinner, with a thickness of about 1/16″ (0.0625″). It provides a smooth surface for high-quality printing and is often used for cosmetic, electronic, and small retail product packaging. Despite being lightweight, it still offers decent strength and protection.
- F-Flute: It is the finest and most compact flute type, measuring only about 1/32″ (0.031″) thick. It is ideal for luxury packaging, folding cartons, and small product boxes where a premium appearance and excellent foldability are important.
If you are still unsure about which flute is the best, you can also read our detailed guide for a better understanding of corrugated flutes.
Types Of Corrugated Cardboard
The corrugated cardboard comes in various types depending on your product’s nature. You can combine flutes and linerboards to get a variety of flute structures.
Here are some of the types of corrugated cardboard available in the packaging market.
- Single Wall – It is composed of one fluted medium between two linerboards. This is the standard structure used for most packaging applications due to its balance of strength and cost-efficiency.
- Double Wall – This features two fluted mediums and three linerboards. It provides increased durability and is suitable for heavier items or products that require extra protection.
- Triple Wall – It is built with three fluted mediums and four linerboards. This high-strength option supports loads up to nearly 300 lbs and is used for industrial or heavy-duty packaging needs.
Different Corrugated Box Styles
You can find various corrugated box styles of construction with various thickness levels. You can use custom corrugated boxes to meet your product requirements. Below are mentioned some of the popular box styles of corrugated boxes:
- Tab Lock Roll End
- Mailer Box
- Shipping Box
- Roll End Tuck Front
- One Piece Folder Box
- Regular Slotted Box
- Gusset Folder
Benefits of Corrugated Boxes
Corrugated packaging is widely favored for its versatility and strength. It is especially beneficial in industries where product protection and sustainability are crucial. Below are the key advantages of using corrugated packaging:
| Benefit | Description |
| Protection and Durability | Corrugated boxes absorb shocks and offer cushioning to prevent damage during transit. They are strong enough to withstand harsh conditions, making them ideal for e-commerce shipping. |
| Environmentally Friendly | It is made from recycled fibers, and corrugated packaging is recyclable and sustainable, supporting eco-friendly business practices. |
| Customizable | Corrugated boxes can be customized in size, shape, thickness, and surface printing. This flexibility ensures a perfect fit for any product, enhancing branding and functionality. |
Where To Buy Custom Corrugated Boxes?
When it comes to custom corrugated boxes, our experts are dedicated to delivering quality packaging solutions. We take every necessary step in quality control to ensure the perfect corrugated box for your needs. Additionally, we offer custom corrugated boxes at wholesale rates for bulk orders, making packaging a cost-effective choice, with free design support and shipping.
