Understanding Corrugated Board: Single Wall, Double Wall, and Triple Wall Packaging
When it comes to packaging, boxes made from a material called corrugated board are among the most commonly used types today. Corrugated board consists of a fluted sheet sandwiched between two flat sheets of paperboard. This type of board is available in different grades and thicknesses, and is classified into three types: single wall, double wall, and triple wall.
Single Wall Board
Single wall board is the most basic type of corrugated board, consisting of a single layer of fluted paperboard sandwiched between two flat sheets of paperboard. Single wall board is available in different grades and thicknesses, and is ideal for packaging applications that require a lightweight and cost-effective solution. It is often used for shipping and storing small items such as books, clothing, and electronics, as well as for product displays, storage bins, and mailers.
Double Wall Board
Double wall board is made by combining two layers of fluted paperboard with three flat sheets of paperboard. This type of board is thicker and more durable than single wall board, and is ideal for packaging applications that require extra protection and strength. It is often used for shipping and storing heavier items such as appliances, furniture, and automotive parts, as well as for industrial packaging, retail displays, and point-of-purchase displays.
Triple Wall Board
Triple wall board is the thickest and strongest type of corrugated board, made by combining three layers of fluted paperboard with four flat sheets of paperboard. This type of board is ideal for packaging applications that require maximum protection and strength. It is often used for shipping and storing extremely heavy items such as machinery, equipment, and bulk products, as well as for pallet boxes, crates, and reusable containers.
Choosing the Right Type of Board
When choosing the type of board for packaging, factors such as the weight and size of the product being shipped or stored, the shipping and handling conditions, and the intended use of the packaging should be considered. Single wall board is suitable for smaller and lighter items, while double wall or triple wall board is necessary for heavier and larger items that require extra protection and strength. For products that require maximum protection against shock, vibration, and impact, triple wall board is the best choice.
Summary: Corrugated Boards Explained
In conclusion, corrugated board is a versatile packaging material that offers various options for different packaging needs. By selecting the right type of board, businesses can ensure that their products are properly protected during transportation and storage.
If you are interested in any stock or custom corrugated packaging, then partner with Brown Packaging today to get started.
In 2026, sustainability is no longer just a trend—it’s a buyer expectation. Forest Stewardship Council (FSC) certification has become a key benchmark for responsible packaging, signaling that materials are sourced from responsibly managed forests. For packaging buyers, FSC certification is more than a compliance checkbox—it’s a brand value that influences purchasing decisions, retailer acceptance, and customer loyalty. What Is FSC Certification? The Forest Stewardship Council certifies that paper-based packaging materials are sourced from forests managed for environmental responsibility, social benefit, and economic viability. FSC Mix: Packaging contains a blend of FSC-certified and controlled wood. FSC Recycled: Packaging is made entirely from recycled fiber. FSC 100%: Packaging is sourced only from FSC-certified forests. Why FSC Matters to Buyers in 2026 Retail access: Many major retailers now require FSC-certified packaging. Sustainability goals: Aligns with corporate ESG and carbon reduction commitments. Consumer trust: Customers recognize the FSC label and view it as credible. Global compliance: Meets international sustainability regulations. How FSC Certification Strengthens Brand Value Differentiation: Stand out with certified sustainable packaging. Marketing advantage: FSC logos reinforce eco-friendly messaging. Risk reduction: Verified sourcing prevents greenwashing claims. Customer loyalty: Environmentally conscious buyers prefer certified products. Challenges in FSC Implementation Limited supply of certain FSC substrates. Higher costs compared to non-certified materials. Need for supplier audits and documentation. Packaging Solutions with Brown Packaging Brown Packaging partners with buyers to integrate FSC-certified materials into corrugated boxes, folding cartons, and retail packaging. Our solutions support sustainability while maintaining cost efficiency and protection. Contact us to strengthen your brand with FSC-certified packaging. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Consumer Insights on Sustainable Packaging. Retrieved from https://sustainablepackaging.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. (714)300-0650 request@brownpackaging.com Most Recent Posts: Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Sustainable Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Sustainability is now a top priority for packaging buyers. Retailers, regulators, and consumers are all demanding packaging solutions that reduce environmental impact without sacrificing performance. In 2026, buyers must balance eco-friendly materials, cost, and compliance to build programs that are both effective and future-ready. What Buyers Need to Know About Sustainable Packaging Regulatory pressure: Governments are enforcing stricter rules on recyclability and plastic use. Retail mandates: FSC certification and recyclable packaging are becoming standard requirements. Consumer expectations: Customers increasingly choose brands with visible sustainability commitments. Sustainable Material Options Recycled corrugated: High recycled content while maintaining compression strength. Compostable films: Suitable for select food and retail applications. Molded pulp inserts: Replace foam or plastic for protective packaging. Water-based coatings: Enhance moisture resistance without harmful chemicals. Balancing Cost and Performance Right-size packaging: Reduces material waste and shipping costs. Hybrid solutions: Combine eco-materials with corrugated for balance. Life cycle analysis: Evaluate true environmental impact, not just marketing claims. How to Evaluate Sustainable Suppliers Verify FSC, SPC, or ISO certifications. Request testing data for durability and recyclability. Audit supply chains for consistency and transparency. Ensure claims meet local and international compliance standards. Packaging Solutions with Brown Packaging Brown Packaging helps buyers implement sustainable packaging programs that balance cost, performance, and compliance. From recycled corrugated to eco-friendly coatings and inserts, we deliver solutions that meet 2026 sustainability goals. Contact us to explore sustainable packaging options. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Packaging Sustainability Trends and Buyer Insights. Retrieved from https://sustainablepackaging.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Sustainable Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Choosing the right packaging material is one of the most important decisions buyers face. Single-material packaging offers simplicity and recyclability, while multi-material designs provide enhanced performance and protection. Understanding the trade-offs helps companies balance cost, functionality, and sustainability goals in 2026. What Is Single-Material Packaging? Single-material packaging uses one substrate—such as corrugated board, folding carton, or plastic—for the entire structure. Advantages: Easier to recycle and dispose. Lower material costs in many cases. Streamlined sourcing and inventory. Supports sustainability messaging. Disadvantages: Limited barrier protection. Less customization for fragile or complex products. May require added thickness for strength, increasing weight. What Is Multi-Material Packaging? Multi-material packaging combines two or more substrates—such as corrugated with foam, or paperboard laminated with film—to achieve specific performance outcomes. Advantages: Greater protection against moisture, oxygen, and impact. Allows for premium finishes and enhanced graphics. Ideal for fragile or high-value products. Customizable for unique supply chain conditions. Disadvantages: More difficult to recycle due to material separation. Higher cost and longer lead times. Complex sourcing and inventory management. When to Use Each Approach Single-material packaging: Best for products with low fragility, strong sustainability requirements, or cost-driven programs. Multi-material packaging: Best for high-value, fragile, or regulated products requiring advanced protection. Balancing Performance and Sustainability Buyers must weigh performance needs against eco goals: Use recyclable coatings to extend single-material performance. Choose hybrid designs that separate easily for recycling. Apply multi-material solutions only where risk of damage outweighs cost. Packaging Solutions with Brown Packaging Brown Packaging helps buyers evaluate when to use single- vs. multi-material packaging. Our team balances sustainability, performance, and cost to deliver solutions tailored to your supply chain. Contact us to explore the right approach for your products. References Forest Stewardship Council (FSC). (2023). FSC Packaging Certification Guidelines. Retrieved from https://fsc.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.Sustainable Packaging Coalition. (2022). Design for Recyclability and Multi-Material Packaging Report. Retrieved from https://sustainablepackaging.org (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
One of the biggest challenges in sustainable packaging is balancing environmental responsibility with product protection. Buyers often worry that switching to eco-friendly materials means sacrificing durability or driving up costs. In 2026, new material technologies allow brands to meet sustainability goals without compromising strength or supply chain performance. Why Protection Still Matters Damaged products create more waste than packaging ever could. Returns increase logistics costs and carbon emissions. Retailers and e-commerce platforms expect packaging to deliver both sustainability and reliability. Eco-Friendly Material Options Recycled corrugated: Maintains stacking strength while reducing virgin fiber use. Molded pulp inserts: Cushion fragile items while replacing plastic foam. Water-based barrier coatings: Add moisture resistance without plastic films. Compostable films: Ideal for short shelf-life or single-use applications. Paper-based mailers: Replace poly mailers for e-commerce shipments. How to Balance Eco Goals and Protection Use right-sizing to reduce material volume while improving fit. Apply hybrid solutions (corrugated + pulp) for high-value goods. Conduct ISTA testing to validate protective performance. Match material choice to product fragility and supply chain conditions. Examples in Action Electronics: Molded pulp trays replacing EPS foam. Food and beverage: FSC-certified corrugated with recyclable coatings. Retail e-commerce: Recycled paper mailers protecting apparel. Packaging Solutions with Brown Packaging Brown Packaging develops eco-friendly solutions that protect products while meeting sustainability requirements. From recycled corrugated to innovative coatings, our team ensures you never trade protection for environmental impact. Contact us to explore eco-material options. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Eco-Friendly Packaging Materials and Case Studies. Retrieved from https://sustainablepackaging.orgASTM International. (2023). ASTM D4169: Standard Practice for Performance Testing of Shipping Containers and Systems. (714)300-0650 request@brownpackaging.com Most Recent Posts: Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
In today’s competitive market, packaging affordability doesn’t start with cheaper materials — it starts with smarter design. Every score, fold, and insert decision affects not only how a box looks and feels, but how efficiently it’s made, shipped, and used. Structural engineering is the silent driver of cost efficiency — optimizing strength, space, and performance before the first sheet is ever printed. Why Structure Matters More Than You Think The most impactful cost savings in packaging rarely come from supplier discounts; they come from structural efficiency.A box that uses 10% less board but maintains the same compression strength directly reduces both material and freight cost. A redesigned insert that eliminates the need for secondary packaging saves time and labor at the line. Every cut line and fold path tells a story of cost, sustainability, and brand care — and when those align, affordability becomes part of your brand’s DNA. Designing for Efficiency, Not Excess In a market saturated with overbuilt packaging, engineering restraint is a competitive advantage. Structural teams now rely on 3D CAD modeling and virtual prototyping to simulate performance before production — identifying unnecessary material use and structural redundancies. Through precision die-line planning, engineers can improve sheet yield, reduce assembly time, and minimize void space — the dead air that drives up freight bills.It’s not about doing less; it’s about doing smarter. Balancing Protection and Presentation The temptation to “overprotect” products is common — especially in fragile or high-value goods. But protection doesn’t have to mean bulk. Strategic reinforcements, engineered fluting, and interlocking designs can maintain crush resistance and shock absorption while reducing total board weight. For e-commerce and shelf packaging alike, brands can achieve premium presentation with structural simplicity — a key to making packaging both sustainable and affordable. Prototyping to Prevent Waste Prototyping isn’t just for aesthetics — it’s a safeguard against costly production errors.With short-run sample testing and performance mockups, brands can evaluate fit, function, and protection early in development. Adjusting dimensions by fractions of an inch can save thousands in material waste and prevent rejected runs down the line. Smart packaging buyers now view prototyping not as an expense, but as a cost-control strategy that pays dividends in scale. How Structural Design Supports Brand and Budget Affordable design doesn’t mean compromising brand identity — it means integrating brand goals into structure. A well-engineered box reinforces trust, ensures product consistency, and communicates value through precision and fit. When structure, design, and production align, packaging stops being a cost and starts becoming a business asset. That’s where the real savings live — and where long-term brand equity begins. The Brown Packaging Difference At Brown Packaging, every packaging solution starts with structural intent — not guesswork.Our engineering and design teams collaborate to create packaging that performs across shipping, retail, and automation lines, balancing protection, brand visibility, and cost efficiency. We don’t cut corners; we cut waste.That’s how our clients achieve packaging that’s not just affordable — it’s engineered to perform. References Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. PMMI. (2024). Optimizing Structural Design for Packaging Efficiency. Packaging World. (2025). Engineering the Future of Cost-Effective Packaging. Smithers. (2025). Packaging Innovation and Material Efficiency Trends. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Every brand is feeling the squeeze — higher raw material costs, volatile freight rates, and a consumer base more price-conscious than ever. But cutting packaging budgets blindly can lead to damaged goods, compliance issues, and eroded brand value. Smart brands aren’t chasing cheaper boxes — they’re making smarter packaging decisions that balance performance, cost, and perception. The difference between saving money and losing value comes down to how you evaluate your packaging, not just what you pay for it. Beyond Unit Price: Understanding Total Packaging Cost A low unit price might look great on paper — until you factor in assembly time, damage rates, and freight efficiency. Smart packaging evaluation considers the total cost of ownership, including: Material yield (how efficiently sheets convert into boxes) Pallet and trailer utilization (freight optimization) Labor efficiency (ease of assembly or automation compatibility) Product protection (damage rates, replacements, and returns) When buyers assess all these metrics, the lowest-cost box often isn’t the best-value box. Material Selection That Saves in the Long Run Switching materials isn’t just about cutting cost — it’s about reducing waste and improving performance. For instance, moving from double-wall to a high-performance single-wall with better flute structure can cut weight and shipping cost without sacrificing protection. In folding cartons, substrate optimization — using a lighter caliper SBS or switching to coated recycled board — can yield savings that scale across production runs. And for rigid boxes, structural tweaks like thinner chipboard paired with strong wrap papers can preserve presentation while reducing material use. Every small change adds up when you scale across thousands of units. Design Efficiency: The Overlooked Cost Saver A smart structural design can eliminate cost before production even starts. Simplifying folds, reducing glue flaps, or reengineering inserts can cut assembly time and material waste. Modern packaging engineers use CAD-based dieline analysis to optimize layouts — ensuring maximum sheet yield and minimal offcut. For e-commerce and retail brands alike, right-sizing packaging improves shipping efficiency and reduces filler materials while maintaining the brand’s polished look. It’s not just design — it’s design that earns its keep Printing Smart: Matching the Process to the Purpose Not every job needs premium litho or complex spot varnishes. A good packaging partner matches print method to scale and brand intent: Flexo printing for high-volume, cost-efficient runs. Digital printing for short runs, personalization, and multi-SKU campaigns. Litho laminating for high-end visuals in rigid or premium retail displays. By choosing the right print method early, brands can avoid over-engineering — saving both time and money without compromising quality. Data-Driven Decisions: The New Standard for Packaging Buyers Leading companies now use data to guide packaging spend. Damage rate metrics, SKU-level freight analysis, and consumer perception studies all contribute to smarter choices. Smart buyers are no longer asking, “What’s the cheapest box?” They’re asking, “What’s the most efficient box that protects the product, ships well, and supports brand goals?” This mindset shift is what separates cost-cutting from cost control. The Brown Packaging Approach At Brown Packaging, we help brands make smarter packaging decisions by combining engineering analysis, supplier network leverage, and real-world testing. Our process aligns packaging performance with total cost goals — from box design to print selection and logistics. The result: stronger packaging, lower waste, and sustainable cost savings that scale with your business. Because in today’s market, smart packaging isn’t just a cost center — it’s a competitive advantage. References PMMI. (2025). Operational Cost Efficiency in Packaging and Logistics. McKinsey & Company. (2024). Total Cost of Ownership in Consumer Goods Packaging. Packaging World. (2025). Data-Driven Decisions in Packaging Sourcing. Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
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Why Board Grade Selection Matters In today’s volatile supply chain environment, packaging failures aren’t just a nuisance—they’re a liability. Damage in transit, product returns, and load instability all lead back to one foundational element: board grade. Whether you’re shipping across the country or staging products for long-term storage, the right corrugated board strength directly impacts product integrity, compliance, and bottom-line efficiency. Understanding Board Grade Classifications Corrugated board grade is defined by its burst strength (measured in pounds), edge crush test (ECT) rating, or basis weight in pounds per 1,000 square feet. The two most common standards: Mullen Test (Burst Strength): Measures resistance to puncture or rupture under pressure (e.g., 200#). Edge Crush Test (ECT): Measures stacking strength and compression resistance along the edge (e.g., 32 ECT). Higher board grades offer greater durability but come at a cost—so matching board performance to supply chain risk is key. How Board Grade Supports Supply Chain Resilience ✔ Reduces Transit DamageHeavier board grades (like 44 ECT or 275#) are essential for heavier items or mixed-pallet shipping. They prevent crushing under load and protect high-value products from collapse or impact. ✔ Improves Stacking StabilityIf your supply chain includes warehousing, transloading, or racking, poor stacking strength leads to bottom-box failures. ECT-rated boxes offer predictable stacking loads, enabling more reliable palletization strategies. ✔ Adapts to Environmental StressorsIn humid or high-temperature zones, lower-quality board can warp or delaminate. Upgrading to moisture-resistant coatings or wax-treated grades extends package integrity in unpredictable conditions. ✔ Meets Carrier and Retailer ComplianceMajor carriers and retailers (e.g., Amazon, Walmart) often require packaging that meets minimum board grade thresholds for specific product categories. Failing to comply can result in chargebacks or denied loads. Matching Board Grade to Application Lightweight Goods (<30 lbs): 32 ECT or 200# is often sufficient for controlled distribution. Midweight/Stacked Goods (30–65 lbs): 44 ECT or 275# single-wall offers better stability. Heavy or Fragile Items: 48 ECT+, 350# double-wall, or even triple-wall is standard for machinery, appliances, or multi-SKU master packs. Export Shipments: Double-wall with moisture resistance is critical for sea containers and extended transit. Why Resilience Now Means Cost Efficiency Later Skimping on board grade may reduce material costs short-term, but it increases risks throughout the supply chain: Higher damage rates Increased return logistics More manual rework at DCs Lower pallet efficiency By engineering packaging with the right board spec, brands can build flexibility into distribution—whether absorbing shock during LTL shipping or maintaining load stability during storage. Final Thoughts Your corrugated board grade isn’t just a spec—it’s a strategic decision that drives supply chain resilience. From minimizing product loss to meeting compliance and stacking standards, choosing the right board means fewer disruptions and greater operational continuity. At Brown Packaging, we help businesses select, test, and implement the right corrugated materials based on real-world demands. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Corrugated Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts
Corrugated boxes are an essential part of the shipping and storage process for businesses worldwide. They are made of corrugated paperboard, which comprises three layers: an inside liner, an outside liner, and a corrugated medium. The fluted medium provides cushioning and strength to the box, while the liners provide a surface for printing and labels. There are several types of corrugated boxes, with full overlap (FOL) being one of the most popular due to its superior strength and durability. What is Full Overlap (FOL) Corrugated Boxes? Full overlap (FOL) corrugated boxes are designed with flaps that completely overlap, providing extra protection to the contents inside. The flaps on both the top and bottom of the box extend all the way to the opposite side of the box, ensuring maximum protection and support. The FOL design provides a stronger and more secure seal than other types of corrugated boxes, making it ideal for shipping and storage of heavy or fragile items. Benefits of Full Overlap (FOL) Corrugated Boxes: Durability and Strength FOL corrugated boxes are known for their superior strength and durability, making them ideal for shipping and storing heavy and fragile items. The complete overlap of the flaps ensures that the box can withstand rough handling during transit without compromising the contents. Protection The complete overlap of the flaps provides an extra layer of protection to the contents inside the box, reducing the risk of damage during transit. The FOL design also prevents dust and dirt from entering the box, keeping the contents clean and protected. Customizable Full overlap corrugated boxes can be customized to fit the specific needs of the contents being shipped. The size and shape of the box can be tailored to fit the contents, and additional cushioning or inserts can be added to provide extra protection. Cost-Effective Despite their strength and durability, FOL corrugated boxes are cost-effective and affordable. They are also recyclable, making them an environmentally friendly choice for packaging. Security These corrugated boxes can be sealed tightly and securely with tape, ensuring that the contents remain inside the box during transit. The secure seal also helps prevent tampering and theft. Branding FOL boxes can be customized with a company logo or branding, providing an opportunity for businesses to promote their brand while also protecting their products. Sustainability Full overlap boxes are made from renewable materials and are recyclable, making them a sustainable packaging choice for businesses. Compliance Corrugated boxes can be designed to comply with various shipping regulations, ensuring that the contents arrive at their destination safely and securely. Full Overlap Box Customization FOL corrugated boxes can be customized to meet specific business needs. Customization options include: Size and shape The size and shape of the box can be tailored to fit the contents being shipped. Custom sizes and shapes can be created to ensure a perfect fit for the products. Printing FOL boxes can be printed with company logos, branding, and product information. This can enhance the customer experience and promote brand awareness. Inserts and Cushioning Additional inserts and cushioning can be added to FOL boxes to provide extra protection for fragile or delicate items. Closure Options FOL boxes can be customized with different closure options, including plastic or paper tape, Velcro, or staples. When to Use Full Overlap (FOL) Corrugated Boxes: FOL corrugated boxes are ideal for shipping and storing heavy or fragile items that require extra protection. They are commonly used in industries such as manufacturing, automotive, and aerospace, where heavy and delicate components are shipped. FOL boxes are also commonly used for packaging equipment, machinery, and electronic devices. In addition, FOL boxes are ideal for shipping and storing items that require long-term storage, as they provide excellent protection against dust, dirt, and moisture. FOL boxes can be used for a variety of products, including: Industrial Full overlap boxes are often used to ship and store large and heavy industrial equipment, such as generators, compressors, and pumps. The boxes can be customized to fit the specific dimensions of the equipment and can be reinforced with additional cushioning or inserts for added protection. Automotive Auto parts such as engines, transmissions, and axles are commonly shipped with full overlap boxes. The boxes can be customized to fit the specific dimensions of the parts and can be reinforced with additional cushioning or inserts for added protection. Electronics These boxes are ideal for shipping and storing electronic devices, such as computers, printers, and televisions. The boxes provide excellent protection against dust, dirt, and moisture, which can damage electronic components. FOL boxes can be customized with additional cushioning or inserts to provide extra protection for delicate electronic components. Medical FOL boxes are commonly used to transport medical supplies, such as surgical instruments, laboratory equipment, and diagnostic kits. The boxes can be customized to fit the specific needs of the contents and can be reinforced with additional cushioning or inserts for added protection. Food and Beverage Food and beverage products, such as canned goods and bottles are often packaged inside this type of box as it provides excellent protection against damage during transit and can be customized to fit the specific dimensions of the products. Retail These boxes can be used to package retail products, such as clothing, shoes, and accessories. The boxes can be customized with branding and logos to promote the brand and enhance the customer experience. E-commerce FOL boxes are commonly used for e-commerce shipments, as they provide a secure and durable packaging solution for products being shipped directly to consumers. Summary: Full Overlap Boxes Explained In summary, Full Overlap (FOL) corrugated boxes are an excellent choice for businesses that require a strong, durable, and protective packaging solution for their products. FOL boxes provide superior protection to heavy or fragile items during transit, and they can be customized to fit the specific needs of the contents being shipped. Customization options include size and shape, printing, inserts and cushioning, and closure options. Whether shipping industrial equipment, automotive parts, electronics, medical supplies, food and beverage
The weight a corrugated box can hold depends on factors such as box construction, material grade, flute size, and box dimensions. Corrugated boxes are designed to protect and hold items during storage and shipping efficiently. A standard single-wall corrugated box can hold between 20 to 120 pounds, while double-wall constructions can support significantly higher weights ranging from 80 to 180 pounds. Understanding Corrugated Box Strength Corrugated box strength is determined by multiple factors, including construction, material grade, and flute size. Understanding these variables ensures the right box is chosen for the job. Box Construction Corrugated boxes are available in three main constructions: Single-Wall Boxes: Suitable for lighter items with weight capacities ranging from 20 to 120 lbs, depending on the material strength. Double-Wall Boxes: Designed for heavier or fragile items, supporting weights from 80 to 180 lbs. Triple-Wall Boxes: Used for exceptionally heavy items, such as industrial equipment, capable of holding hundreds of pounds. Material Strength: Bursting Test and Edge Crush Test (ECT) Two key measurements determine corrugated box strength: Bursting Strength Test: Measures the force required to rupture the surface of corrugated board. Edge Crush Test (ECT): Measures stacking strength and indicates how much weight a box can withstand before collapsing. The following tables summarize the equivalencies for single-wall and double-wall corrugated boxes: Single-Wall Corrugated Boxes Bursting Test Minimum Edge Crush Test (ECT) Maximum Suggested Loading Limit Per Carton 125# 23 ECT 20 lbs. 150# 26 ECT 35 lbs. 175# 29 ECT 50 lbs. 200# 32 ECT 65 lbs. 275# 44 ECT 95 lbs. 350# 55 ECT 120 lbs. Double-Wall Corrugated Boxes Bursting Test Minimum Edge Crush Test (ECT) Maximum Suggested Loading Limit Per Carton 200# 42 ECT 80 lbs. 275# 48 ECT 100 lbs. 350# 51 ECT 120 lbs. 400# 61 ECT 140 lbs. 500# 71 ECT 160 lbs. 600# 82 ECT 180 lbs. These standardized tests ensure the durability and reliability of corrugated boxes, helping buyers choose boxes that meet their weight requirements. The Role of Flute Size Corrugated boxes use fluted sheets to provide strength and cushioning. Larger flutes (like A or B flutes) offer better compression resistance and are ideal for heavier items, while smaller flutes (like E or F flutes) provide a smoother surface for printing and are better for lightweight items. The Importance of Box Dimensions Box size directly affects weight capacity and strength. Larger boxes have a wider surface area, which can distribute weight evenly but may require stronger materials to prevent collapse. Choosing the appropriate box size can optimize load support and minimize material waste. How to Choose the Right Box To ensure optimal performance, consider the following when selecting a corrugated box: Determine the Weight of the ContentsUse the tables above to match the weight of your products with the appropriate box strength. Evaluate the Box Construction Single-wall for lightweight items. Double-wall for medium to heavy items. Triple-wall for extremely heavy or industrial goods. Consult with SuppliersCollaborate with packaging experts to select boxes with the proper ECT or bursting strength for your application. Optimize for SustainabilityChoose boxes made from recycled or sustainable materials without compromising strength. Conclusion The weight a corrugated box can hold depends on its construction, material grade, and strength ratings (ECT and bursting test). Single-wall boxes can hold up to 120 lbs, while double-wall boxes can support weights up to 180 lbs, as shown in the tables above. By understanding these key metrics and factors, packaging buyers can confidently choose the right boxes for their needs, ensuring products are protected during shipping and storage. Partner with Brown Packaging today to find corrugated boxes designed to meet your weight, size, and durability requirements. Whether you’re shipping lightweight goods or industrial equipment, we’ve got the solution for you! (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Corrugated Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts