What is a Corrugated Box?
Corrugated boxes are made up of multilayer fiberboard that consist of a top liner, flute in the middle, and an inner liner. This material is designed to be sturdy and highly durable material. Corrugated boxes are used everyday by all industries for shipping and product display purposes. Often, many people mistake corrugated material for cardboard, which is not the proper term.
Corrugated boxes can be manufactured using either a machine run process or a die-cutting process, depending on the specific design and requirements of the box.
In general, machine run boxes are produced by feeding a continuous roll of corrugated board through a machine that cuts, scores, folds and glues the material into the desired box shape. This process is often used for standard, simple box designs with straight edges and minimal customization. Examples are RSC, HSC, FOL and Gaylord boxes.
On the other hand, die-cutting is a process in which a custom-made metal die is used to cut and crease corrugated board into a specific shape or design. This process is ideal for creating complex box designs, such as those with handles, windows, or unique shapes. Examples are tuck end, roll end tuck top, folders, trays, bin boxes and others.
Custom Corrugated Box Applications and Solutions
Corrugated boxes, often referred as cardboard boxes, are extremely versatile in use, as a result they are one of the most common used packaging product worldwide. Here are some of the most popular corrugated packaging applications we can help you with, but are not limited to:
Popular Applications
In the world of e-commerce, effective packaging is essential for shipping and delivery. Packaging solutions come in various sizes to accommodate products of different shapes and sizes, ensuring safe and cost-effective shipping to customers. Learn more about our ecommerce packaging solutions.
Food companies rely on dependable packaging solutions to store and transport their products, including fresh produce and canned goods. These solutions adhere to strict food safety standards, preserving product integrity and freshness. Checkout our food packaging solutions.
Beverage manufacturers require reliable packaging solutions to store and transport their products, ensuring the safe delivery of beverages while maintaining their quality and appeal. View our beverage packaging solutions.
Industrial applications require sturdy and dependable packaging solutions for storing and transporting heavy machinery parts, tools, and industrial equipment, providing protection against wear and tear. Visit our industrial packaging page.
The electronics industry relies on protective packaging solutions to safeguard delicate electronic components and devices during shipping and storage, minimizing the risk of damage. Learn more about our electronic packaging page.
Common Solutions
Single-print packaging solutions offer cost-effective customization with a single design on the exterior. Ideal for businesses looking to optimize branding while maintaining a consistent look across various products and industries.
Multi-print packaging allows for diverse and eye-catching designs on different panels of the packaging. This versatile solution caters to industries where visual impact and product differentiation are crucial, such as retail, cosmetics, and electronics.
Custom packaging designed specifically for product display helps businesses create enticing in-store presentations. These solutions enhance product visibility and are often used in retail environments to attract and engage customers effectively.
Shipping boxes are engineered for secure and efficient transportation of products. Sturdy and durable, they provide protection during the shipping process and are commonly used in e-commerce, manufacturing, and distribution industries.
Subscription boxes offer a delightful unboxing experience for customers receiving regular shipments. These customized solutions cater to various subscription services, from cosmetics and snacks to books and lifestyle products. Learn more about our subscription boxes.
Designed to protect bicycles during shipping or storage, bike boxes are durable and sturdy solutions, often featuring extra padding and specialized compartments. They are essential for manufacturers, retailers, and bike enthusiasts. Learn more about our bike boxes.
Custom Corrugated Box Styles
Selecting the right custom corrugated box style is crucial for optimizing your packaging solution. Our range includes options like RSC (Regular Slotted Container), RETT (Roll End Tuck Top), FOL (Full Overlap), and more, each designed to suit specific packaging needs. Choosing the appropriate style ensures that your products are not only well-protected during storage and transportation but also efficiently presented, contributing to a seamless packaging experience for both businesses and customers.
Corrugated Box Customization
Print Options
Flexography (also known as flexo) is a printing process that uses flexible relief plates made of rubber or photopolymer to transfer ink onto various substrates, such as corrugated, plastic films, and paper. It is a high-speed, cost-effective printing method that is suitable for printing on rough, porous, and irregular surfaces.
Digital print refers to a printing method that uses digital files such as PDFs, JPEGs, or TIFFs as a source for printing images or text. Digital print technology has revolutionized the printing industry by offering faster turnaround times, lower production costs, and the ability to produce high-quality prints
Lithography is a printing technique that uses a flat printing plate, a special kind of ink, and oil-based or water-based liquids to transfer an image onto a substrate. It produces high-quality, sharp and clear prints that are suitable for printing high-resolution graphics and text.
Graphic Design
Graphic design must reflect the brand identity and effectively communicate the brand’s message to customers.
Maximize product visibility by apply graphics with contrasting colors, bold text, and high-quality images.
The text used in the graphic design must be legible, both from a distance and close up. The font size, color, and style must be carefully selected to ensure that the text is easily readable
Have your graphics effectively utilize the space available on the display, including the sides and back, to maximize impact and exposure to the product.
Display relevant product information, such as product name, benefits, and features. This information should be presented in a clear and concise manner.
Create a design consistent with the brand’s overall design and marketing materials, ensuring a cohesive look and feel across all channels.
Flexible designing, allowing for the display to be easily updated as needed, without requiring a complete redesign.
View your product with a realistic 3-D rendering that is easily sharable. Renderings are ideal for reviewing display prototypes and enabling quick and cost effective edits and changes.
Finishes
A gloss finish is a shiny and reflective surface that is achieved by applying a gloss varnish over the printed surface. This finish enhances the vibrancy and saturation of the colors and makes the printed graphics appear more eye-catching.
A matte finish is a non-glossy surface that has a flat and velvety texture. This finish provides a subtle and sophisticated look and reduces glare, making it ideal for printing products that require a professional look.
Spot UV is a printing technique that involves printing a clear UV varnish in specific areas of the printed surface to create a glossy texture on specific parts of the design. This finish adds depth and texture to the printed graphics and enhances the overall appearance of the product.
Litho lamination is a finishing process that involves bonding a printed piece to a thick layer of paper, plastic or film. This finish provides extra protection to the printed surface, makes the product more durable, and enhances the overall quality of the product.
There are many other finishes we can apply to your custom display such as a varnish, die-cutting, perforation, scoring, film lamination, creasing, hot foil stamping, blind embossing and others.
Strength & Thickness
Single wall corrugated material is the thinnest option, typically ranging from 200 to 500 microns in thickness. This option is suitable for lightweight products and provides a cost-effective solution for boxes.
Double wall corrugated material is thicker than single wall and typically ranges from 600 to 1000 microns in thickness. This option provides additional strength and stability to the box and is suitable for heavier products.
Triple wall corrugated material is the thickest option, typically ranging from 1000 to 1500 microns in thickness. This option provides maximum strength and stability to the box and is suitable for very heavy products.
The most common ECT (Edge Crush Test) rating for custom corrugated boxes is typically between 32 and 44. ECT is a measure of a box’s strength and its ability to resist crushing under pressure, which is an important factor in determining the durability and protection of the packaged product during shipping and handling.
Burst ratings for corrugated boxesrange from 200 to 400, with higher numbers indicating greater strength and durability. A burst rating of 200 is suitable for lightweight products, while a burst rating of 400 is recommended for heavier products.
Corrugated Packaging Services
Add more value to your product and packaging experience with our in-house capabilities and services. Work one on one with a project specialist throughout the entire packaging process with services designed to help you meet your goals and maximize your results, while providing you with peace of mind.
Expert Consulting
Our expert consulting services provide tailored guidance and strategic insights to help you make informed packaging decisions and optimize your packaging processes.
Digital Print
Utilizing advanced in-house digital printing technology, we offer high-quality printed samples that showcase your packaging design concepts effectively.
Structural Design
Our structural design expertise ensures your packaging is not only visually appealing but also optimized for functionality, protection, and cost-efficiency.
Sampling
We provide sampling services to help you evaluate and refine your packaging prototypes, allowing you to make data-driven decisions before full-scale production.
Graphic Design
Our graphic design team specializes in creating captivating visuals, ensuring your packaging communicates your brand identity and product messaging effectively.
Product & Material testing
We offer comprehensive product and material testing to guarantee the durability, safety, and compliance of your packaging, assuring its suitability for your specific industry and requirements.
