RSC Packaging Cost Efficiency
RSC boxes are widely used because they balance strength with cost efficiency. But not all RSC boxes are created equal. Buyers have to weigh board grade, flute profile, and design factors to avoid overpaying for unnecessary strength or, worse, underpaying and risking product damage. Understanding these trade-offs ensures that packaging budgets are optimized without compromising protection.
Board Grade and Cost Trade-Offs
- Higher Grades (e.g., 44 ECT)
- Provide greater stacking strength.
- Necessary for heavy products, palletized loads, or export packaging.
- Higher cost due to stronger liners and mediums.
- Lower Grades (e.g., 26–32 ECT)
- Ideal for lightweight products.
- Cost-effective for single-use shipments or direct-to-consumer e-commerce.
- Reduce material cost but lower compression resistance.
Takeaway: Over-specifying board grade adds unnecessary cost. Match strength to actual product weight and stacking requirements.
Flute Profiles and Efficiency
- B-Flute: Good balance of cushioning and stacking strength, widely used in RSC.
- C-Flute: Higher cushioning, thicker profile, similar cost per unit.
- E-Flute: Thin profile, less stacking strength but reduces material use and shipping cost for small/light products. Higher cost per unit.
Takeaway: Flute choice affects not only performance but also dimensional weight — a critical factor in freight costs.
Assembly and Material Costs
- Tape and Labor: RSC requires tape or glue for sealing, which adds to per-unit cost at scale.
- Automation: Automated case erectors reduce labor, but box tolerances must be consistent to avoid jams.
- Material Utilization: RSC has one of the most efficient board utilization rates, reducing waste compared to specialty die-cut mailers.
Freight and Storage Efficiency
- Cube Utilization: Right-sizing RSC dimensions reduces dimensional weight charges.
- Palletization: Box dimensions affect how many units fit per pallet — poor fit can increase freight by 10–15%.
- Knock-Down Storage: RSC ships flat, minimizing inbound logistics costs and warehouse space.
Buyer Takeaway
- Use lower board grades for lightweight e-commerce and non-palletized shipments to save cost.
- Reserve higher grades for industrial, heavy-duty, or export applications.
- Right-size your RSCs to minimize dimensional weight surcharges.
- Consider automation compatibility to reduce long-term labor expense.
When optimized, RSC packaging isn’t just cost-efficient — it’s a lever for total supply chain savings.
References
- Fibre Box Association. (2023). Corrugated Cost Optimization. https://www.fibrebox.org
- Association of Independent Corrugated Converters (AICC). (2024). Cost and Efficiency in Corrugated Packaging. https://www.aiccbox.org
- Robertson, G. (2016). Food Packaging: Principles and Practice (3rd ed.). CRC Press.
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Corrugated boxes play a vital role in the packaging industry, offering durability and versatility for shipping and storing various products. To ensure the safe transportation and identification of goods, packaging products such as tape, stretch film, labels, inserts, void fill, dunnage bags, bubble wrap, edge protectors, and shrink wrap are commonly used in conjunction with corrugated boxes. Quick Overview: Packaging Products for Corrugated Boxes In this blog post, we will explore the significance, applications, and benefits of utilizing these packaging products with corrugated boxes. Tape Stretch Film Labels Inserts Void Fill Bubble Wrap Edge Protectors Shrink Wrap Tape Tape is an essential packaging product used to secure corrugated boxes, ensuring the products inside remain protected during transit. It comes in various materials, including plastic, paper, and cloth. Plastic tape is widely used due to its cost-effectiveness and strong sealing properties, while paper tape offers an eco-friendly option with a natural appearance. Cloth tape is ideal for heavy-duty packaging requirements. Benefits of using tape with corrugated boxes include: Protection: Tape securely seals corrugated boxes, safeguarding the products during transportation. Customization: Tape can be tailored to fit different sizes and shapes of corrugated boxes. Convenience: Tape is easy to use and can be applied manually or with a tape dispenser. Stretch Film Stretch film is a versatile packaging product used to provide an additional layer of protection to corrugated boxes. It safeguards products from dust, moisture, and other environmental factors during transit, while also minimizing product movement. Benefits of using stretch film with corrugated boxes include: Protection: Stretch film offers an extra layer of protection for products during transportation. Customization: Stretch film can be customized to fit various sizes and shapes of corrugated boxes. Convenience: Stretch film can be applied manually or with specialized machines. Labels Labels play a crucial role in identifying the contents of corrugated boxes and providing essential information about the products. They can indicate the box contents, product weight, handling instructions, and branding details. Benefits of using labels with corrugated boxes include: Identification: Labels provide vital information about the products inside the boxes. Customization: Labels can be designed and customized to fit specific labeling requirements. Convenience: Labels can be easily affixed to corrugated boxes manually or using labeling machines. Inserts Inserts are employed to protect products within corrugated boxes, preventing movement and minimizing the risk of damage during transportation. Common materials used for inserts include foam, cardboard, and plastic. Benefits of using inserts with corrugated boxes include: Protection: Inserts provide additional protection by securing products in place during transit. Customization: Inserts can be tailored to fit the shape and size of corrugated boxes. Convenience: Inserts are easy to use and can be manually placed within the boxes. Void Fill Void fill is used to occupy empty spaces within corrugated boxes, reducing product movement and enhancing protection. It is particularly useful for fragile items such as glassware, electronics, and ceramics. Void fill materials include paper, foam, and inflatable plastic. Benefits of using void fill with corrugated boxes include: Protection: Void fill prevents products from shifting and minimizes the risk of damage during transportation. Customization: Void fill can be adjusted to fit the specific box size and shape. Convenience: Void fill is easy to use and can be manually placed within corrugated boxes. Bubble Wrap Bubble wrap is a popular packaging product known for its cushioning properties, making it suitable for protecting delicate items such as glassware, electronics, and ceramics. It consists of plastic material with air bubbles. Benefits of using bubble wrap with corrugated boxes include: Protection: Bubble wrap provides effective cushioning and safeguards fragile products during transportation. Customization: Bubble wrap can be cut to fit the size and shape of the products and boxes. Convenience: Bubble wrap is easy to use and can be wrapped around products manually. Edge Protectors Edge protectors are designed to protect the corners and edges of products within corrugated boxes. They are commonly used for items like furniture, appliances, and electronics. Benefits of using edge protectors with corrugated boxes include: Protection: Edge protectors prevent damage to product corners and edges during transportation. Customization: Edge protectors can be customized to fit various box sizes and shapes. Convenience: Edge protectors are easy to use and can be manually applied. Shrink Wrap Shrink wrap is a packaging product used to secure and protect products within corrugated boxes during transportation. It involves wrapping a plastic film around the products and applying heat to shrink and conform it to their shape. Benefits of using shrink wrap with corrugated boxes include: Protection: Shrink wrap provides secure and tamper-evident packaging, protecting products from external elements. Customization: conforms to the shape of products and corrugated boxes. Convenience: can be easily applied manually or with shrink wrap semi or fully automatic machines. If you are interested corrugated boxes or other types of packaging, then partner with Brown Packaging today to get started. (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 terms cardboard and corrugated are often used interchangeably, but in packaging, they mean very different things. Cardboard is a catch-all term used by consumers, while corrugated and chipboard each have specific material definitions and applications. Knowing the difference helps buyers choose the right packaging solution and avoid costly mistakes. Corrugated: Material and Products Corrugated material is built from at least three layers: an inside liner, an outside liner, and a fluted medium in between. Additional layers can be added to improve compression and stacking strength. This structure makes corrugated ideal for protective and high-strength packaging. Products Made with Corrugated Boxes (RSC, FOL, die-cut mailers, etc.) POP displays Dividers and partitions Edge protectors Sheets and inserts Corrugated is available in natural kraft brown or bleached white. The brown color often leads consumers to mistakenly call it “cardboard.” Chipboard: Material and Products Chipboard (sometimes called paperboard) is manufactured by pressing small wood particles with resin under heat and pressure to form a smooth, rigid sheet. While it is lightweight and inexpensive, it does not provide the same compression or stacking strength as corrugated. Products Made with Chipboard Folding cartons for small, lightweight goods Dividers and partitions Inserts and sleeves Chipboard is commonly used in retail-ready cartons for cereal, cosmetics, and lightweight consumer goods. Like corrugated, it typically appears in white or brown, reinforcing the consumer misuse of the word “cardboard.” Why the Difference Matters Using the wrong material for packaging can affect cost, product safety, and supply chain efficiency. For example: Corrugated is essential when structural strength and stacking are required (shipping boxes, displays, bulk distribution). Chipboard works when lightweight retail packaging is sufficient (folding cartons, retail sleeves). Referring to corrugated as “cardboard” may cause confusion when sourcing from suppliers who distinguish between the two. Selecting the right supplier also matters — not all packaging providers manufacture or stock both corrugated and chipboard. Working with one that does ensures consistent quality, efficiency, and fewer inventory issues. Corrugated Box Folding Carton (Chipboard) Work With Brown Packaging At Brown Packaging, we help businesses choose between corrugated, chipboard, and other packaging materials based on product needs, cost goals, and supply chain requirements. Whether you need protective shipping boxes or retail-ready cartons, our team can guide you through every step. Contact Brown Packaging today to get started. References Fibre Box Association. (2023). Corrugated Material Basics. Retrieved from https://www.fibrebox.org Paperboard Packaging Council. (2023). Chipboard and Folding Carton Applications. Retrieved from https://paperbox.org Soroka, W. (2016). Fundamentals of Packaging Technology (5th ed.). Institute of Packaging Professionals. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Folding Carton Display Packaging Rigid Box 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