What is Corrugated box ( Technically called as Corrugated fibreboard carton)

You are wondering that what is a corrugated box than we can come up with a single definition that when a flute paper which is made by compressing the Kraft containerboard in the shape of S arch and then sandwiched between the linear board with the help of the adhesive. This sheet is called a corrugated sheet and the box made out of it are called corrugated box.

Why we use corrugated box?

Well, there cannot be one particular answer to this as there are many advantages of using a corrugated box. This lightweight box can provide enough protection against the packed goods. We can look at the following points to understand the advantage of using a corrugated box.

  • Corrugated box are much stronger than cardboard box
  • Can be recycled and reused are made of biodegradable material
  • Corrugated box offers flexibility and are also cost-effective
  • Sustainable and cost-efficient
  • Corrugated boxes are easily customizable and provides branding option.
  • They are cost-effective, lightweight and provide sustainability.
  • The Corrugated box is designed in such a way that it helps to protect the product from moisture and bacteria.

Thus, is a great option for the packaging of food products ex: – Corrugated pizza box

Difference between corrugated vs card boxes

If you considered the cardboard box as same as corrugated box than you are having a lot of confusion in your head. Yes, they are not the same at all. Corrugated box are specially designed for shipping and packaging of larger products such as home appliances, or products which needs to be shipped with great care. Due to its durability, lightweight and product protection it is a better choice over cardboard box.

Cardboard boxes are generally made up of a single layer of sheet with heavy paper-pulp. The Cardboard box is generally used as packaging material in the form of a cereal box, greeting boxes, food products, etc.
The main difference between corrugated box and cardboard box is the process through which they are built. Though the raw material used in the manufacturing of both type of boxes is the same. The construction is pretty much different, the corrugated box usually consists of 3 or more than 3 layers of linear board with a flute sandwiched between them which increases the overall durability of the box. Whereas the cardboard box is made of a single sheet of heavy paper-pulp which is less durable as compared to corrugated boxes

3 PLY corrugated box

What is 3 Ply?

3 Ply is a term used for Single Wall Corrugated Sheet. It is made of Top Liner, Fluting Medium & Back Liner.

It is chosen based on application of packaging & other factors such as characteristics of shipping. 

3 Ply Corrugated Carton

  • To Ship round, cubic or odd-shaped items.
  • To Ship bulk product from one site to another.
  • Easy to load/unload.
  • Protects irregular loads.
  • Consolidate several small shipments.
  • Impact & Moisture Resistant
  • Higher Strength & Lighter Weight
  • Dimensional Accuracy
5 PLU corrugated box

What is 5 Ply?

5 Ply is a term used for Double Wall Corrugated Sheet. It is made of Single Top Liner, Double Fluting Medium & Double Back Liner.  It is chosen based on application of packaging & other factors such as characteristics of shipping. Generally used for heavier products where stacking are required.

5 Ply Corrugated Carton

Double the protection of a 200 lb. test box. 

Protects valuable, fragile or your heaviest items.

Use when extra stacking strength is needed.

Recommended Weight Capacity is 40 Kgs

DIE CUT box

Die cut boxes are highly customizable corrugated cardboard boxes designed to fit any shape, size, or need. They are known as die cut boxes because they are cut from plain sheets of corrugated material on a machine known as a die press (or die cutter).

Die cut boxes are first designed by engineers or design specialists, then the die press is set and configured to cut the cardboard. After the boxes are cut they can be further customized by adding unique graphics that may include product information, warnings, or company logos.

Featured with perforated lines or access holes, the provided box can be bought from us in customized sizes, finishes, prints and designs. It is manufactured with the use of premium quality raw materials and sophisticated machines by a crew of dexterous professionals. Also, the offered box is fit for the packaging of crockery sets to prevent breakage during shipping from one end to another.

Die Cut Corrugated Cartons

  • Used in Food Packaging, Electronics Items, Gifts
  • Easy to Ship, Hold & Use
  • Consumer Centric Ergonomics
  • High Strength & Lightweight
  • Impact & Moisture Resistant
  • Dimensional Accuraracy
CUSTOM PRINTED box

Branding is a need of an hour and the same should reflect through your packaging at first. We encourage our customers to go for Custom Printed Corrugated Boxes for their various requirements. We can print up 6 colors in printing through Flexographic Printing.

Corrugated Boxes can be more attractive if printed with Logo, Brand Name & Other details of Business. In most cases, the boxes are often custom printed as the cost of printing is minimal.

Custom Printed Corrugated Box

  • Used in Various Industries & Products
  • Easy to Ship, Hold & Use
  • Consumer Centric Ergonomics
  • High Strength & Lightweight
  • Impact & Moisture Resistant
  • Dimensional Accuracy
WHITE box

White Corrugated Box are specifically required for some of the customers where the print-ability is appraised. Also, White Boxes offers a premium look than the ones with brown colour. We can product white cartons made from Duplex Paper of Higher Grade.

Die Cut Corrugated Cartons

  • Premium Appearance
  • Used in Food Packaging, Electronics Items, Gifts
  • Easy to Ship, Hold & Use
  • Consumer Centric Ergonomics
  • High Strength & Lightweight
  • Impact & Moisture Resistant
  • Dimensional Accuracy
MULTIDEPTH Box

Multi Depth Corrugated Boxes are in demand as it helps reduce packaging inventory to a great extent as well as it offers saving in terms of transportation cost. Sides are creased at intervals – Just cut to the creased height needed, fold down and you have a custom size carton.

Multi-depth corrugated boxes help ensure a perfect fit for packages to prevent potentially harmful in-box movement. If a product or item is too small for the corrugated box that houses it, it’s easy for damage to occur, since the product will have plenty of room to wiggle around and bang against the walls during transportation.

Whether it’s meant to hold a fragile glass bowl or a plastic tool, multi-depth corrugated boxes snugly surround each item to guard against cracking, scratching and other damage that may occur during the delivery process.

Multi Depth Cardboard Box​

  • Used in Food Packaging, Electronics Items, Gifts
  • Easy to Ship, Hold & Use
  • Consumer Centric Ergonomics
  • High Strength & Lightweight
  • Impact & Moisture Resistant
  • Dimensional Accuraracy

Type of corrugated box

Now, as if you have got an idea about a corrugated box. Then we should dig deeper into different types of corrugated boxes used in different sectors of industries according to their durability, the protection they provide and the capacity of handling the weight.

There are mainly four types of corrugated box, single-phase corrugated box, single wall corrugated box, double-wall corrugated box, triple wall corrugated box. We will have a look at the difference between them and their application in various industries.

Single-phase corrugated
type of corrugated sheet consists of a single flute and one or two sheets of linear board. The flute is glued to the linear board. Single-phase corrugated are usually sold in the form of sheet rolls and are most commonly used to wrap around product for protection or cushioning.

Single wall corrugated box
type of corrugated box consists of a one sheet of corrugated medium which is glued and placed between two sheets of liner board. This type of corrugated box has multiple uses in retail industries and as shipping boxes.

Double wallboard
walled corrugated boxes consist of a two-layer of corrugated medium glued between three layers of liner board. Hence, it makes the box more rigid and can be used for packaging of heavy products or products which are more delicate. This type of corrugated is widely used in shipping of electronic products.

Triple wallboard
one which is strongest of all type of corrugated box consist of three layers of corrugated medium and four-layer of liner board. Triple wall corrugated boxes are mainly used in packaging of industrial parts due to their durability and higher burst strength

Different thoe of flutes used in corrugated box

Types of flutes

(A) Single Face: One corrugated medium is glued to one flat sheet of linerboard; flutes exposed.
(B) Single Wall: The corrugated medium is glued between two sheets of linerboard. Also known as doubleface.
(C) Double Wall: Three sheets of linerboard with two mediums in between.
(D) Triple Wall: Four sheets of linerboard with three mediums in between

What does a flute means in a corrugation? Well, different types of flute are used in corrugated box among which the most commonly used is Flute C which is used in more than 80% of corrugated boxes. The different type of flute has been made for different purpose.

FLUTE FACTS 

Corrugated board can be created with several different flute profiles. Generally, larger flute profiles deliver greater vertical compression strength and cushioning. Smaller flute profiles provide enhanced structural and graphics capabilities for use in retail packaging.

The five most common flute profiles are:
A-Flute: Appx 33 flutes per foot or 300mm. Original corrugated flute design. For 100mm there will be around 11-12 flutes so around 33 flutes per foot . This will have flute stretch of 30mm will be50mm. The height / thickness is 5.1-5.2mm.

A flute


B-Flute: Appx 47 flutes per foot and measures 1/8″ thick; often for canned goods. At the length of 100mm this will have 16 flutes so there will be around 47-48 flutes per foot or 300mm. The flute stretch of 30mm will be 32-3mm. The overall height is 2.8-3mm.

B flute


C-Flute: Appx 39 flutes per foot and measures 5/32″ thick; common for shipping cartons. At 100mm length there will be 13 flutes so around 39 flutes per foot or 300mm. The flute stretch of 30mm will be 42mm . The height of this flute with liner and back sheet is 3.9-4.0mm.

C flute


E-Flute: Appx 90 flutes per foot and measures 1/16″ thick. At 100mm length the number of flutes will be 27 flutes so there will be (27×3= 88) 88-90 flutes per foot or 300mm. . The flute stretch of 30mm would be around 27mm and overall height of back sheet + flute + liner is 1.6-1.8mm.

E flute
Flutes arranged from top to bottom (A/C/B/E).the blue line marked is 30mm length to count the number of flutes.


F-Flute: Appx 125 flutes per foot and measures 1/32″ thick; for small retail packaging.

Different flute profiles can be combined in one piece of combined board. For example, a triplewall board may contain one layer of A-flute medium with two layers of C-flute medium. Mixing flute profiles allows designers to adjust compression strength, cushioning strength and total thickness of the combined board.

Type A Flute
Corrugated box containing type A flute has excellent compression and cushioning as well as good stacking strength. This type of corrugated box is mainly used to pack fragile items. The corrugated box Contains 36 flute per square foot with a thickness of ¼.

Type B Flute
The box containing type B flute is excellent in resisting puncture and flat crush. It is a great option for printing. This type of flute is commonly used in inner packing and displays. It has 46 flutes per foot with a thickness of 1/8.

Type C Flute
This type of flute is used in corrugated box which are used in building shipping boxes, box for food products and for securing fragile items like glass or furniture. It has compression properties and crush resistance. It also provides a good printing surface.

Type E Flute
Type E Corrugated boxes are commonly used in the packaging of consumer goods, displays, and ballot box and food products ex: – Corrugated pizza box. The box containing E type flute has very thin construction and thus it consumes less storage space. It has a superior printing surface and crush resistance. It contains 90 flutes per foot with a thickness of 1/16.

Type F Flute
The box containing F Flute are lightweight and are extra thin as compare to other flute. It is an excellent choice for printing purpose thus it is used for packaging of consumer goods like jewelry, shoes, etc. It has 124 flutes per foot with a thickness of 1/32. Make it excellent in terms of crush resistance

Style of corrugated box

You are going to find a lot of different styles of corrugated boxes used for different purpose. Used for different purpose let us look at different styles of corrugated boxes.

Regular slotted Container (RSC)
This type of box is most commonly used. As you think of corrugated box the first thing to come in your mind is the image of the box given above. It has four flaps which are on both sides of the box used for closing the container.

Full Overlap Container (FOL)
The type of box is similar to RSC expect that the outer flap set covers the full width of the container. This type of corrugated box has extra thickness on top and bottom makes it a better option for products that need extra protection.

Half Slotted type
type of corrugated box has a similar structure as regular slotted expect it has opening on one side. Thus it helps in providing extra protection to the product.

Telescope type
type of box has separate top and bottom that fits on each other thus providing extra thickness and protection on all the four sides. This type of box is used in the packaging of fragile products.

Fold type & tray
type of boxes are often used in the packaging of food products. It comes in mainly two types Glues tray and Self-locking tray boxes. Other than that there are more customizable style of tray box such as slotted tray, tray with top flaps (e.g.:- corrugated pizza box), display tray and much more.

Other than this there are a lot of different types of corrugated boxes available in the market. Which can be used for fulfilling a different purpose

HOW TO MEASURE A BOX 

Dimensions should always be stated in the sequence of LengthWidth and Depth(exceptions include bookfolds, bin boxes and dividers, where the sequence is Width, Length and Depth).

The length is always the longer dimension, and the width is always the shortest dimension, measured along the opening of the box. The depth is the distance between the opening and the opposite panel.

Boxes are generally measured from the inside, with the dimensions referring to the opening of an assembled box. Inside dimensions are used for measuring because the corrugated board thickness may vary. A box constructed of B flute will not have the same outer dimensions as a box made from E flute. When measuring the inside of an existing box, make sure to measure from the center of the score (the crushed fold line).

Outer dimensions may need to be communicated for shipping and pallet configuration purposes. When listing outer dimensions, always include “OD” with the size (e.g., 10″x22″x12″ OD).

SLOTTED BOXES

These boxes are generally made from a single piece of corrugated fiberboard. The blank is scored and slotted to permit folding. Boxes are shipped and stored flat and assembled as needed by the user. Some of the most common types include:

Regular Slotted Container (RSC) — All flaps have the same length, and the two out flaps are one-half the container’s width, so that they meet at the center of the box when folded. The RSC is the most common box style.

Half Slotted Container (HSC) — Same as a Regular Slotted Container (RSC), but without one set of flaps.

Overlap Slotted Container (OSC) — All flaps have the same length; the outer flaps overlap by one inch or more. The box is usually closed with staples driven through the overlap area. This style of box is used when the length of the box is considerably greater than the width, resulting in a long gap between the inner flaps. The sealed overlap helps to keep the outter flaps from pulling apart.

Full overlap Slotted Container (FOL) — All flaps have the same length (the width of the box). When closed, the outer flaps come within one inch of complete overlap. This style is especially resistant to rough handling and provides extra product cushioning and stacking strength.

Center Special Slotted Container (CSSC) — Inner and outer flaps are cut to different lengths. Both sets of flaps meet at the center of the box. This style is especially strong because both the top and bottom have double the thickness of corrugated board. The inner flaps, with no gap, provide a level base for products.

Center Special Overlap Slotted Container (CSO) — All flaps have the same length (one-half the length of the box). The length of the box can be no more than twice its width. The inner flaps meet at the center of the box, providing a level base and full top protection.

Center Special Full Overlap Slotted Container (SFF) — Inner and outer flaps are cut to different lengths. When closed, the inner flaps meet at the center of the box, and out flaps fully overlap. With three full layers of combined board over the entire top and bottom, this style provides extra cushioning and stacking strength.

TELESCOPE BOXES

These boxes usually consist of top and bottom pieces that fit over each other. “Telescope Style” generally describes a box where the cover extends over at least two-thirds of the depth of the bottom piece, where a Box with Cover indicates a box where the cover extends less than two-thirds of the depth. Common types include:

Full Telescope Design Style Container (FTD) and Design Style Container with Cover (DSC) — Two-piece boxes made from two scored and slotted blanks (trays).

Full Telescope Half Slotted Container (FTHS)— The two-piece body is made from two half-slotted containers.

RIGID (BLISS) BOXES

Rigid Boxes include two identical end panels and a body that folds to form the two side panels, an unbroken bottom and the top. Flaps are used to form the joints. Once the joints are sealed, the box is considered rigid.

SELF-ERECTING BOXES

Self-Erecting Boxes typically feature regular slotted container or telescope-style tops.

FOLDERS

These consist of one or more pieces of combined board, with an unbroken bottom surface and scored to fold around the product. Popular styles include:

One Piece Folder (OPF) — One piece of board is cut so that it provides a flat bottom, with flaps forming the sides and ends, and extensions of the side flaps meeting to form the top.

Five Panel Folder (FPF) — A single cut and scored piece features a fifth panel used as the closing flap, completely covering a side panel.

Trays are formed from a single piece of combined board, with the design featuring an unbroken bottom and several layers of corrugated in the end panels. They are frequently used as inner containers for parts, delicate produce or mail pieces.

INTERIOR FORMS

These include a wide variety of build-ups, dividers, partitions and other inner packing pieces. They can be used to separate or cushion products, to strengthen the box or to fill voids. They may be simple rectangle, scored, slotted or die-cut shapes. Common formats include:

Pads are plain shapes of corrugated or solid fiberboard, used to fill spaces or separate layers or sections of products.

Tubes are scored rectangles, folded to form a multi-sided structure.

Partitions (or Dividers) provide a separate cell for each item in a box. Primarily used for packaging glassware or other fragile items.

Inner Packing Pieces are scored and/or folded pieces of fiberboard used for cushioning, suspension and separation, and to fill voids.

Inner Pack Forms are usually die cut fiberboard pieces designed to position and support products away from the walls of the box for added protection.

FIBERBOARD PERFORMANCE STANDARDS

Type of printing in corrugated box

For branding on a corrugated box, we can rely on different types of printing methods. All of these printing methods have different application in packaging industries.

Lithography
type of printing are most commonly used in consumer product boxes. E.g.:- corrugated pizza box, cosmetic box, electronic box, etc. It has a high print quality and ca be used for higher perceived value like matte or super gloss. This type of printing can be seen on folding cartons and labels.

Flexo
type of printing is mainly used in large scale industries where corrugated boxes are required for shipping purposes. It has less printing cost per unit, lower tool cost and can be printed using both water and oil-based inks. It is mainly used for printing stand up pouch, corrugated box for shipping.

Digital printing
type of printing can be done with low-cost setup and can be used if the volume is less. It’s print quality is comparable to lithography. And the final product can be produced quickly. It is mainly used in printing labels, film for flexible packaging, etc.

Rotogravure
printing technique can produce excellent quality prints. Can be used to print photos and images it can print large volume without any deterioration in print quality. It is used to print flex pouches and folding carton.

Silkscreen
print can mainly be seen on bottles, caps, mugs, and t-shirts. It has a low-cost setup and can be used for smaller volume. It is used to print labels, prototype, promotional items, and folding carton

What should be kept in mind while buying corrugated box?

If you are having a business like a franchise of a pizza shop and looking for corrugated pizza box for packaging or having a custom handmade product to be shipped to your customer or anything else which includes corrugated box in it. Then you must know that what to look at before you choose which type and style of corrugated box among them is the most suitable one for you.
To check this we need to know that where would be this corrugated box is going to be used and once we are familiar with it we can go through a checklist to follow up and get the most suitable box for our need.

What does GSM in corrugated box mean?
GSM in corrugated box means Gram per square meter which means the amount of ply used in building the corrugated box. The higher GSM Shows that the more durability of the corrugated box and higher bursting strength.

What is the burst factor in the corrugated box?
Bursting strength defines the amount of pressure the paper can tolerate before it raptures. In a corrugated box, the no of ply and flute paper increases the durability of the carton and thus it increases the bursting strength.

Which product I am putting in the carton?
purpose of buying any specific corrugated box must be known before you buy any one of them. As there are many styles of corrugated box available in the market you should choose the one which is most suitable for your particular industry.

Which grade of corrugated box will my package require?
grade of corrugated box is an important factor if you want your product to be safely delivered to your customer. This grade can be decided by checking the Composition, Type of paper used, GSM, and Type of Flute.

Where would be the box used?
is an important question to ask yourself before ordering corrugated box. As if you want to use it for packaging of consume product or it is needed for shipping purpose. Because it will help you to decide which type, style and printing you will be using on them.

Which printing method is best for you?
you have decide the style and type of corrugated box now you need to decide the process of printing that you want to use on corrugated box. If it is for consumer product than you can go for digital printing and lithography. If it is for shipping than you can go for flexo and if it is for custom made then you can choose silkscreen

What are the quality parameters of corrugated box? General quality parameters of corrugated boxes are bursting strength of the board, compression strength of a board, ring crush test, edge crush test, weight of the box, GSM of the paper used, moisture measurement & moisture resistance, also known as cobb value.

How do you test the bursting strength of the box? To test the bursting strength of the multi-layered papers and paperboards, high-quality of bursting strength testers with the superior quality of diaphragm is used. During the test, the sample is pressurised with uniform pressure until the seal or weakest point of the box or paper burst

How do you measure the compressive strength of the box? The compressive testing process. A concrete compressive strength test machine works by progressively applying force on a specimen. Because strength is defined as the maximum load carried divided by the average cross-section area, the most logical way to determine the strength of a specimen is to load it until it fails.

What kind of adhesives are used in corrugated box? The adhesive is used to form a bond between top liner & fluting media. The stronger the bond, better the box. Starch based adhesive is used to make corrugated boxes

How the joints are done to make a box? There are 2 types of method available. First is to use stitching pins to in flap to form a box. Also, there are varieties of stitching pins like, stainless steel, brass & copper.

End….

The above information is collected and compiled for printers and print buyers reference purpose only.

Happy Learnings K.Panthala Selvan

Pressman if offering wide range of tools and equipments for material testing and process control. Below link can give you an idea of the tools. More tools will also be added shortly.

Contact us for more details.

https://pressmansolutions.in/material-testing-solutions/

Published by Panthala Selvan

Authorised partner for Kodak prepress workflow, Techkon Spectrodensitometers, cip3 solutions, colour management, packaging development etc

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out /  Change )

Google photo

You are commenting using your Google account. Log Out /  Change )

Twitter picture

You are commenting using your Twitter account. Log Out /  Change )

Facebook photo

You are commenting using your Facebook account. Log Out /  Change )

Connecting to %s

%d bloggers like this: