The corrugated boxes are essential for daily life operations. They are so significant that the world cannot operate without them. A simple buying guide is below if you want to buy the boxes.

The corrugated boxes are incredibly beneficial in the operation of the economy today. You can find them in almost all sectors, from medical to engineering. Furthermore, their versatile use ensures you can use them for home, office, or commercial purposes.

In short, corrugated boards are a must-have. The best thing about them is that they are recyclable. For instance, you can use your freezer’s box to store unused items. Thus, no one goes under loss after purchasing the corrugated containers.

Many products that ship in corrugated boxes remain in the containers because of the convenient storage. Moreover, the retail packaging boxes serve several functions before they get to the recycling plant.

Thus, the corrugated packaging industry is currently on an exponential rise. Furthermore, the increase in e-commerce, especially with the pandemic, has increased its demand. Also, more and more consumers desire eco-friendly packaging options, thus ensuring ready demand for corrugated boxes.

Corrugated Box in Packaging Deconstructing

The first step in understanding the corrugated boxes is noting that they are different from cardboard boxes. The terms often confuse most people. However, the cardboard is heavy-duty paper, and its standard function is folding cartons.

In most cases, the folding carton boxes are present on grocery shelves because of the cardboard material. Some of the most common folding cartons are in cheese, mac, or cereal boxes. The box-type cannot guarantee you to survive during shipping. If you place them carelessly, there is a high chance that they will get to you in tatters.

On the other hand, a corrugated box is all about durability and strength. The box has a medium and liner that ensures it can survive shipping. Manufacturers make it using three layers of fiberboard. There are also cases when a customer can request for the board to be thicker.

The outer board’s layer is a liner, or you can also refer to it as a linerboard. The linerboard material is flat, and it is present on the outer side of the board. In the triple or double-wall cases, the liner is on the inside.

The medium is a flute, and it is a wavy layer. The medium is responsible for giving the corrugated packaging box the quality of being strong. It is also why the boxes are almost the standard storage and shipping containers. 

What are the procedures that ensure the manufacturing of corrugated packaging boxes?

The corrugated boards’ cycle begins from a tree. On their own, they undergo manufacturing processes till the manufacturers get the final object. The Corrugated box process includes:

• The manufacturers cut down the tree and then strip off the bark.
• They then grind the logs to become wood chips.
• The manufacturers use a chemical, sulfate or sulfite, to pulp the woodchips in a mechanical pulping procedure.
• A corrugated rolling machine is responsible for making the fluting. 
• The machine glues and presses the board’s layers together.
• Then a die cutter is used to cut out elements such as cores, creases, and flaps.
• It is glued after the board cutting, thus forming the corrugated box.

Corrugated Boxes: It all begins as a paper

Two primary paper manufacturers use to test and kraft to make the corrugated boards. The test paper is often used as the board’s inner liner, while the kraft paper is present in the box’s outer liner.

The kraft paper has a higher quality and is more costly than the test paper regarding quality and pricing. Kraft paper comes from softwood trees, like fir, spruce, and pine; it has 70%-80% virgin pulp chemical fiber. It also has various versions, like birch-faced, fully bleached, mottled, white, and brown.

Kraft paper has a smooth finish, which is better for customization, like printing. The paper is also water-resistant. The water resistance ensures that the box has an extra protection amount, ensuring that products are safe from water damage.

Moreover, the kraft paper plays an essential role in ensuring that a corrugated fiberboard has a higher burst and tear resistance. If you compare it to test paper, you will find that the kraft paper is stronger.

Test liners come from hardwood trees that contain fibers, like the Chestnut, Birch, Sycamore, Oak, or even recycled paper. Test paper is cheaper than kraft; however, it is difficult to print on and less durable. The test paper’s properties ensure that its best position is inside the box.

The Different Flute Grades for a Corrugated Box

The flute is the wavy part of a corrugated box. It is also the critical differentiator between cardboard and the corrugated box.

The flute size is responsible for determining the box walls’ thickness, giving it stacking strength. Various letters distinguish a box’s size. Below are some of the standard flute sizes:

• A-Flute: It is the largest flute with a thickness of ¼ inches. The box’s thickness ensures that it is ideal for fragile products as it gives an extra layer of protection.
• B-Flute: it has a thickness of 1/8 inches and consists of 47 flutes per linear foot. If you compare the A and B-flute, you will find the B-flute is thinner. Despite its size, the flute is also strong. Most manufacturers use the B-flute in making containers for canned goods. Moreover, the flute is famous for its die-cut designs.
• C-Flute: It has a thickness of 3/16 inches and consists of 39 flutes per linear foot. The c-flute is a very trendy shipping option for most boxes.
• E-Flute: It has a thickness of 1/16 inches and consists of 90 flutes per linear flute. The E-flute’s strength is not similar to that of the A of B-Flute. However, it is perfect for folding carton boxes. It is suitable for printing and acts as an excellent material for product display.
• F-Flute: It has a thickness of 1/32 inches and consists of 125 flutes per linear foot. The flute is the thinnest grade and has a smooth surface, making printing very easy.

How to select a suitable custom corrugated boxes wall type

After knowing the flute sizes to expect in the corrugated boxes, next, you should focus on the wall type. If you think about heavy-duty shipping, you should consider the most suitable wall type. Here are some of the wall options for a corrugated packaging;

• Single Face Wall- Corrugated box suppliers often sell the single face wall in rolls. It is a single-liner sheet glued to one medium corrugated sheet. The wall type is perfect for anyone who ships delicate items, such as wine glasses.
• Single-Wall: It contains a single corrugated medium sheet pasted between two liner sheets. The single wall is very common, and it is often the first thing that comes to mind when people think of a corrugated cardboard box.
• Double-Wall: if you compare the single wall to the double-wall, you will find that it is less flexible but more durable.
• Triple Wall: The wall type is the strongest among the corrugated box wall types. It has three corrugated sheets that are stacked and four linerboards. Most manufacturers use it as industrial parts.

Packaging styles of corrugated boxes

Another element that you should look for when selecting a corrugated packaging box for your needs is size and shape. One of the reasons why size is crucial is that your products may cram with the wrong box size. Thus it is better to avoid a too large or too small box.

When choosing a box size, consider its internal dimension. Most box dimensions are as Length*Width*Height (L*W*H). Below are some of the corrugated box styles;

• Full Overlap Container (FOL): The outer box falls, creating a total overlap, making the box strong. Moreover, it has double layers on the bottom and top, adding extra strength to the box.
• Regular Slotted Container (RSC): The RSC is one of the most common shipping boxes present in the market. All of the box’s flaps have equal lengths. The box’s outer flaps meet in the middle when you close it. Also, it requires tape to secure the box flaps.
• Full Telescope Design (FTD): The box’s bottom and top are separate; thus, they fit over each other. The double wall ensures extra strength.
• One Piece Folder (OPF): It is slotted and creased before folded into the corrugated packaging. OPF is common in boxes that package items like books.

When it comes to boxing closing, the most common types are; tapes, strapping, and tuck-in flaps. All the different box choices may confuse you on which is the best. However, you can find several services and tools to assist you in your quest.

Moreover, software options like Impact, Package, and ArtiosCAD can help you design die-cut templates. They are also helpful for 3D modeling. You can also ask for a free consultation for guidance about varnish, box styles, and die lines.

Conclusion

Buying a corrugated box is not as straightforward as most would think. The buying process needs serious consideration in all aspects of the box. Thus, the above can give you an insight into the different corrugated box styles, walls, and flutes.