Home » Folding Carton Vs Rigid Boxes: Which One Should You Choose?
Folding Carton Vs Rigid Boxes: Which One Should You Choose?
When it comes to packaging your products, the choice between folding cartons and rigid boxes is crucial. Both types serve similar purposes in protecting, displaying, and promoting products but differ significantly in their construction and usage implications. This guide provides an in-depth comparison to help you decide which packaging solution best suits your product plans, budget, and business goals.
Understanding Folding Cartons and Rigid Boxes
What is A Folding Carton?
Folding cartons are typically made from thin paperboard, precisely cut, folded, and glued to form a variety of shapes and sizes. These cartons are versatile, customizable, and widely used across various industries for lightweight, durable, and cost-effective packaging solutions.
Folding Carton Benefits
• Cheaper in costs: folding cartons are less complex and are generally made with cheaper material than rigid boxes.
• Storage space efficient: cartons have the flexibility of folding flat, which makes it ideal for storage purposes.
• Lower logistics costs: with lightweight material and a flat structure, cartons are cheap in overhead for shipping and handling.
• Faster to produce: typically, the simpler the packaging product is the faster it is able to be produced.
Folding Carton Disadvantages
• Less product protection: the material used to create folding cartons are thinner compared to rigid boxes.
• Product set-up required in fulfillment: packagers usually have to fold the carton into its form.
• Cannot hold heavy or fragile items: this type of box is not recommended in holding fragile or heavy items.
Common Folding Carton Applications
• Food snacks
• Cereal
• Small electronic devices and accessories
• Soda packs
• Medicine
• Consumer goods (small)
• Sports accessories
• Nutrition and supplements
• Ink cartridges
What is A Rigid Box?
Rigid boxes are made from heavier cardboard than folding cartons and are non-collapsible. Known for their strength and premium quality, these boxes offer enhanced protection and an elevated unboxing experience, often used for luxury or high-value products.
Rigid Box Benefits
• Higher perceived product value: rigid boxes provide customers with more confidence due to your investment in the products packaging (display and promotion)
• Product set-up is easier in fulfillment: these boxes are delivered in their box shape, which will require less labor in fulfillment.
• Superior product protection: these boxes provide extra protection compared to other boxes.
Rigid Box Disadvantages
• More expensive to make: the cost of materials and effort to make rigid boxes is substantially more than a folding carton.
• Slower to Produce: these boxes are more complex, which often result in slower production.
• Higher logistics costs: these boxes are not as logistic friendly as cartons.
• Requires more storage space: boxes have to be stacked and cannot lay perfectly flat like a foldable box.
Common Rigid Box Applications
• Gift boxes
• Cosmetic and beauty set boxes
• Medical devices
• High-end and luxury products
• Jewelry
• Smartphones and computers
Comparison and Considerations
When choosing between folding cartons and rigid boxes, consider the following aspects:
- Product Type: The nature of the product, its fragility, and value play crucial roles. Rigid boxes are preferable for delicate or premium items, while folding cartons are sufficient for more durable and lower-value products.
- Budget Constraints: Folding cartons are more budget-friendly, especially for large volumes, making them suitable for businesses looking to minimize costs.
- Brand Image: The packaging contributes significantly to brand perception. Rigid boxes often convey a higher quality image, appropriate for luxury brands or premium product lines.
- Environmental Impact: Consider the sustainability of your packaging choice. Both options can be produced with recycled materials, but the overall environmental impact may vary based on the production process and materials used.
Final Recommendation
Your decision should align with your overall marketing strategy, product requirements, and customer expectations. If presenting a luxury image or ensuring the utmost protection is crucial, rigid boxes are the best choice. However, if cost efficiency and practicality are more significant concerns, folding cartons will serve well.
If you are interested in rigid boxes or folding cartons, then partner with Brown Packaging today to get started.
Subscription packaging continues to expand across beauty, food, lifestyle, and specialty products. Buyers must balance branding, protection, and sustainability while keeping fulfillment efficient. This checklist highlights the critical areas buyers should review in 2026 when sourcing or redesigning subscription packaging. Branding and Unboxing Experience Seasonal or rotating graphics to keep unboxing fresh. Premium finishes such as foil, embossing, or unique die-cuts. Easy-open features like tear strips for convenience. Right-Sizing and Efficiency Reduce DIM charges with packaging tailored to product sizes. Use modular designs to cover multiple SKUs with fewer box sizes. Ensure packaging works with automation to speed fulfillment. Protection and Durability Inserts that prevent product shifting during transit. ISTA-tested designs to withstand vibration and drops. Moisture-resistant coatings for temperature-sensitive items. Sustainability Requirements FSC-certified corrugated or recycled substrates. Recyclable coatings or compostable options. Clear sustainability messaging to support consumer expectations. Cost Control SKU rationalization to limit unnecessary box variations. Material selection that balances protection and price. Supplier contracts that secure pricing for seasonal peaks. Packaging Solutions with Brown Packaging Brown Packaging designs subscription packaging that combines branding, protection, and sustainability. From FSC-certified corrugated to custom inserts, our solutions help buyers create packaging that builds loyalty and controls costs in 2026. Contact us to review your subscription packaging program. References Sustainable Packaging Coalition. (2023). Subscription Packaging and Consumer Insights. Retrieved from https://sustainablepackaging.orgForest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgInternational Safe Transit Association (ISTA). (2023). ISTA Testing Procedures for Transport Packaging. Retrieved from https://ista.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. Ecommerce Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
As budgets tighten in 2026, packaging buyers are under pressure to reduce costs without increasing damage rates. Cutting too aggressively can lead to product loss, higher return rates, and frustrated customers. The key is balancing material use, box design, and supply chain efficiency so that savings do not come at the expense of protection. Where Packaging Costs Add Up Oversized boxes: Drive dimensional weight charges. Excess materials: Overuse of void fill and inserts. Complex SKU mix: Redundant sizes increase inventory costs. Inefficient freight: Poor palletization and stacking. Cost-Saving Strategies That Maintain Protection Right-sizing: Match box size to product dimensions to cut DIM charges and material use. Optimize corrugated grades: Switch to single- or double-wall where appropriate without compromising strength. Consolidate SKUs: Streamline packaging options to reduce inventory overhead. Efficient inserts: Replace foam or excess dunnage with engineered corrugated or molded pulp. Supplier contracts: Negotiate based on annual volumes, not just peak season orders. Testing Before Implementing Changes Use ASTM and ISTA protocols to ensure changes won’t increase product damage. Test for compression, vibration, and drop resistance. Run pilot shipments before scaling across the supply chain. Balancing Sustainability and Cost Eco-friendly doesn’t have to mean expensive: Use recyclable coatings to reduce plastic films. Choose corrugated designs that require less material while maintaining stacking strength. Highlight sustainable solutions in marketing to offset cost concerns. Packaging Solutions with Brown Packaging Brown Packaging helps companies lower costs while protecting products across the supply chain. From SKU rationalization to right-sized corrugated solutions, our team ensures packaging savings don’t compromise performance. Contact us to optimize your packaging program. References Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.ASTM International. (2023). ASTM D4169: Standard Practice for Performance Testing of Shipping Containers and Systems.Sustainable Packaging Coalition. (2023). Packaging Efficiency and Waste Reduction 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
Product damage is one of the most expensive risks in packaging. Beyond replacement costs, damaged goods lead to lost sales, returns, and reputational harm. In 2026, complex e-commerce, global shipping, and automation create new challenges for packaging buyers. The right materials, testing, and design strategies are critical to protecting products while controlling costs. Why Damage Prevention Matters Financial losses: Damaged products increase replacement and freight costs. Customer impact: Poor delivery experience reduces loyalty and repeat sales. Sustainability: Returns and waste drive higher carbon footprints. Compliance: Retailers often impose penalties for damaged shipments. Common Causes of Product Damage Compression: Pallet stacking weakens boxes in transit. Vibration and shock: Long-haul shipping increases risk. Moisture exposure: Humidity and rain compromise corrugated performance. Poor right-sizing: Oversized boxes allow product movement inside. Strategies to Reduce Damage in 2026 Right-size packaging: Minimize empty space and movement. Material optimization: Choose the correct corrugated grade for load demands. Protective inserts: Molded pulp or engineered corrugated reduce shock. Moisture-resistant coatings: Defend against water and humidity. Automation-friendly design: Prevent jams that damage products on high-speed lines. Testing Protocols for Damage Prevention ISTA testing: Simulates vibration, drops, and compression. ASTM standards: Validate packaging strength and durability. Pilot shipments: Real-world trials confirm lab results. Packaging Solutions with Brown Packaging Brown Packaging designs solutions that minimize damage across today’s complex supply chains. From right-sized corrugated to ISTA-tested inserts, we help buyers protect products while reducing costs. Contact us to strengthen your packaging program. References ASTM International. (2023). ASTM D4169: Standard Practice for Performance Testing of Shipping Containers and Systems.International Safe Transit Association (ISTA). (2023). ISTA Testing Procedures for Transport Packaging. Retrieved from https://ista.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. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Retail packaging continues to evolve as brands balance sustainability, supply chain performance, and consumer experience. In 2026, buyers face new challenges shaped by material innovation, compliance requirements, and rising consumer expectations. Understanding these trends helps companies stay competitive while aligning packaging programs with industry standards. Sustainability Becomes Non-Negotiable Greater use of recyclable and compostable substrates. Retailers pushing suppliers toward FSC-certified materials. Minimalist designs that reduce waste without losing impact. Smarter Packaging for Supply Chains Increased adoption of right-sizing to reduce freight costs. Boxes designed for automation and faster fulfillment. Stronger corrugated grades to withstand long e-commerce journeys. Enhanced Consumer Experience Custom graphics for seasonal campaigns and limited editions. Tear strips, resealable closures, and window cutouts for convenience. Premium finishes that elevate gift packaging at retail. Growth of Hybrid Packaging Formats Combining corrugated strength with folding carton graphics. Modular designs for multi-SKU and club store environments. Packaging engineered to serve both e-commerce and in-store needs. Compliance and Testing Standards Retailers demanding ISTA and ASTM testing for packaging durability. Supply chain audits on recyclability and sustainability claims. More pressure for transparent reporting on environmental impact. Retail Packaging Solutions with Brown Packaging Brown Packaging helps brands adapt to evolving retail packaging trends. From sustainable substrates to automation-friendly designs, our solutions balance branding, durability, and compliance for 2026. Contact us to prepare your packaging program for the year ahead. References Forest Stewardship Council (FSC). (2023). FSC Packaging Certification Guidelines. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Packaging Trends and Consumer 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. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Supplier contracts can make or break a packaging program. Without the right terms, buyers risk price volatility, missed lead times, and inconsistent product quality. In 2026, negotiating smart contracts is essential for controlling costs, securing reliable supply, and meeting compliance requirements. Why Packaging Contracts Matter Cost stability: Protects against sudden raw material price spikes. Supply security: Ensures availability during peak demand. Quality control: Aligns suppliers with testing and compliance standards. Operational efficiency: Streamlines purchasing and reduces administrative burden. Key Terms Buyers Should Negotiate Volume commitments: Secure better pricing with accurate forecasts. Price adjustment clauses: Define when and how costs can change. Lead times and delivery windows: Avoid shortages and production delays. Testing and compliance: Require ISTA, ASTM, or FSC certification where applicable. Sustainability commitments: Ensure suppliers align with environmental goals. Risks of Weak Contracts Paying inflated prices during market fluctuations. Receiving inconsistent corrugated strength or print quality. Missed shipments leading to costly expedited freight. Difficulty meeting retailer or regulatory compliance. Best Practices for Buyers in 2026 Leverage data: Use past order history to negotiate realistic volumes. Dual sourcing: Maintain backup suppliers for risk management. Annual reviews: Reassess terms to reflect changes in demand and compliance. Collaborative approach: Treat suppliers as partners, not just vendors. Packaging Solutions with Brown Packaging Brown Packaging helps buyers secure strong supplier contracts that balance cost, quality, and supply chain reliability. Our partnerships and industry expertise ensure your packaging program is protected for 2026 and beyond. Contact us to discuss supplier solutions. References Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.Fiber Box Association. (2024). Corrugated Packaging Market Outlook. Retrieved from https://www.fibrebox.orgSustainable Packaging Coalition. (2023). Supplier Standards for Sustainable Packaging. 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
Packaging compliance is no longer optional—it’s a requirement for accessing retail shelves, shipping networks, and international markets. In 2026, buyers must navigate evolving regulations around sustainability, labeling, and testing to avoid costly fines, rejected shipments, or damaged customer relationships. Why Compliance Matters in 2026 Retail requirements: Major retailers demand FSC, ISTA, and sustainability certifications. E-commerce standards: Carriers enforce dimensional weight and package testing rules. Global trade: Export packaging must comply with ISPM 15, ASTM, and ISO guidelines. Consumer trust: Transparency in packaging claims impacts purchasing decisions. Key Compliance Areas for Buyers Material sourcing: FSC-certified corrugated and board for sustainability. Labeling standards: GS1-compliant barcodes and accurate product details. Durability testing: ISTA and ASTM protocols for drop, vibration, and compression. Sustainability regulations: Requirements for recyclable or compostable materials. Chemical restrictions: Compliance with FDA, EU, or state-specific standards. Common Compliance Challenges Keeping up with frequent regulatory changes. Managing multiple certifications across suppliers. Balancing compliance with cost-efficiency. Verifying supplier claims for sustainability. Best Practices for Staying Compliant Audit suppliers annually to confirm certification validity. Run internal packaging tests before scaling. Track regulatory updates for each region you ship to. Work with experienced partners who understand industry compliance. Packaging Solutions with Brown Packaging Brown Packaging helps buyers meet 2026 compliance standards with FSC-certified materials, ISTA-tested designs, and regulatory expertise. Our team ensures your packaging meets retailer, carrier, and sustainability requirements. Contact us to keep your program compliant. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgInternational Safe Transit Association (ISTA). (2023). ISTA Testing Procedures for Transport Packaging. Retrieved from https://ista.orgGS1. (2024). Global Standards for Packaging and Labeling. Retrieved from https://www.gs1.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
Home » Folding Carton Vs Rigid Boxes: Which One Should You Choose?

Functional features like tear strips, windows, and hang tabs can enhance consumer experience and retail appeal—but they also introduce engineering challenges. Each modification affects structural strength, converting efficiency, and cost. This guide examines the technical considerations behind these common folding carton enhancements. Tear Strips Tear strips provide controlled access while maintaining tamper evidence until opened. Engineering Considerations: Placement: Must be positioned where it aligns with grain direction to avoid unpredictable tearing. Substrate Reinforcement: Removal of fibers weakens the panel; select caliper and fiber strength to compensate. Activation Features: Starter notches or pull tabs improve usability but require precise die-cut tolerances. Applications: Snack boxes, e-commerce ready-packaging, and promotional multi-packs. Windows Die-cut or film-covered openings that provide product visibility. Engineering Considerations: Board Strength Loss: Removing material reduces panel rigidity—reinforce with flanges or use thicker caliper. Film Selection: Polyester (PET) for clarity and strength; polypropylene (PP) for flexibility and cost savings. Attachment Method: Heat sealing for hermetic barriers; cold glue for standard retail windows. Applications: Bakery cartons, toy packaging, premium electronics. Hang Tabs Extensions with die-cut holes designed for pegboard display. Engineering Considerations: Load Bearing: Must withstand repeated handling without tearing; reinforced with lamination or added plies. Hole Shape: Rounded edges distribute stress better than sharp corners. Placement: Maintain center alignment for balance during display. Applications: Small electronics, blister card sleeves, impulse-buy products. Score and Perforation Modifications Used for easy-open panels or controlled folding in promotional displays. Engineering Considerations: Perforation Pattern: Ratio of cut-to-land determines tear resistance. Score Depth: Must be consistent to avoid tearing in unintended areas. Coating Impact: Gloss or film coatings may require modified perforation tooling for clean separation. Impact on Production Efficiency Die-Cutting Complexity: Additional features increase make-ready time and tooling wear. Feeding and Folding: Non-standard cutouts may catch on machine guides—prototype testing is critical. Waste Management: Window scrap and added features increase offcut volume. Balancing Aesthetics, Function, and Strength Every feature trades some structural integrity for consumer or retail benefit. The engineering goal is to design enhancements that maximize usability and shelf presence without compromising carton performance or running efficiency. References Soroka, W. (2014). Fundamentals of packaging technology (5th ed.). Institute of Packaging Professionals. ISBN: 978-1-930268-37-2 Twede, D., & Goddard, R. (2021). Cartons, crates and corrugated board: Handbook of paper and wood packaging technology (2nd ed.). DEStech Publications. ISBN: 978-1-60595-120-5 (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 Folding Cartons Facebook Twitter LinkedIn Pinterest Relevant Posts

High-speed automated packaging lines can run hundreds of cartons per minute, but only if the carton’s design and material are optimized for smooth feeding, folding, and sealing. Small structural or material missteps can lead to jams, misfeeds, and costly downtime. This guide covers the critical design, tolerance, and substrate considerations for folding cartons intended for high-speed automation. Dimensional Accuracy Automated lines demand tight dimensional control in die cutting. Die Cut Precision: Carton blanks must be within ±0.015 inches for consistent feeding and folding (Soroka, 2014). Blank Squareness: Even minor skew can cause issues with glue flap alignment or panel folding. Caliper Consistency: Variations in board thickness can change fold behavior and sealing pressure. Scoring and Creasing Profiles High-speed folding relies on scores that create predictable, repeatable folds. Score Depth and Bead Width: Too shallow causes spring-back; too deep risks cracking. Bead/Channel Ratio: Must match board caliper and fiber composition for clean folding at speed. Grain Direction: Scores parallel to grain can crack if bead pressure isn’t optimized. Glue Flap Design Flap dimensions and positioning are critical for automated glue application. Flap Width: Minimum 10–12 mm recommended for cold glue; narrower flaps risk bond failure. Glue-Free Zones: Essential near scores to prevent squeeze-out during folding. Coating Considerations: Gloss varnish or film lamination in glue areas requires corona treatment or glue type adjustment for proper adhesion. Material Selection Not all boards perform equally on automated lines. SBS: Smooth feeding, excellent fold consistency, best for high-graphic retail cartons. CUK: Added stiffness and moisture resistance for cold chain or beverage applications. FBB/Recycled: Economical, but may need adjusted scoring to reduce cracking at speed. Folding Sequence Compatibility Structural design must align with the machine’s folding sequence. Tuck End Cartons: Ensure flap lengths are balanced to avoid collision in the folding belts. Auto-Bottom Designs: Verify glue flap and lock panels don’t bind during machine erection. Full Seal End: Flap lengths and bevel angles must accommodate sealing jaws without interference. Surface Coatings and Friction Carton surfaces influence how blanks travel through feeders and conveyors. High Gloss Coatings: Can cause feeding slippage; mitigated with anti-slip varnish zones. Poly Coatings: Increase stiffness but may alter fold memory—test for score cracking before production. Matte Varnish: Generally more forgiving in high-speed feeders. Machine Trials and Prototyping Before committing to a production run: Run on the Target Machine: Testing on actual equipment verifies compatibility. Check Across Speed Range: A carton may run well at 100 cpm but fail at 300 cpm. Inspect Post-Run Samples: Look for misaligned folds, glue squeeze-out, or score fractures. References Soroka, W. (2014). Fundamentals of packaging technology (5th ed.). Institute of Packaging Professionals. ISBN: 978-1-930268-37-2 Twede, D., & Goddard, R. (2021). Cartons, crates and corrugated board: Handbook of paper and wood packaging technology (2nd ed.). DEStech Publications. ISBN: 978-1-60595-120-5 (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 Folding Cartons Facebook Twitter LinkedIn Pinterest Relevant Posts

Board caliper—the thickness of paperboard—directly influences carton strength, folding behavior, print quality, and cost. Selecting the right caliper is a balancing act between performance requirements and budget. This guide explains how caliper affects carton engineering and when it makes sense to go thicker—or thinner. Defining Board Caliper Board caliper is measured in thousandths of an inch (points) or millimeters. Common folding carton calipers range from 0.012″–0.024″ (12–24 pt). Thicker boards offer greater rigidity and stacking strength, while thinner boards reduce weight and material cost. Structural Performance Compression Strength: Higher caliper increases edge crush resistance and stacking load capacity. Panel Rigidity: Reduces bowing and warping, important for large-panel cartons. Impact Resistance: Added thickness absorbs more shock during handling. Trade-Off: Excess caliper can over-spec the package, adding unnecessary cost and complicating folding on small-radius scores. Folding and Creasing Caliper affects how the board behaves at fold lines: Tighter Radii: Thicker boards need deeper scores to avoid spring-back. Score Cracking Risk: Increases with caliper if scoring isn’t adjusted for bead/channel ratio. Grain Direction Sensitivity: More critical in thicker boards—incorrect grain can cause severe cracking. Print Quality and Surface Smoothness Ink Holdout: Heavier calipers often provide better ink laydown, but fiber quality matters more than thickness alone. Show-Through Prevention: Thicker boards reduce show-through from dark products or graphics on the reverse side. Cost Implications Material Cost: Increases proportionally with caliper. Shipping Weight: Higher caliper increases per-unit mass, affecting freight cost. Storage Volume: Larger stacks and more pallet space required. Optimization Tip: Use the thinnest caliper that meets performance requirements—extra thickness adds cost with no functional benefit. Application Examples High-Strength Needs: 20–24 pt CUK for beverage carriers or frozen food requiring moisture resistance and stacking strength. Premium Branding: 18–20 pt SBS for cosmetics or electronics, balancing rigidity with a smooth print surface. Cost-Driven Retail: 14–16 pt recycled FBB for dry food or lightweight multipacks. Testing Before Scaling Prototyping: Test multiple calipers for rigidity, folding performance, and visual appeal. Distribution Simulation: Run compression, vibration, and humidity testing to confirm performance. Machine Compatibility: Thicker boards may require slower speeds or equipment adjustments. References Soroka, W. (2014). Fundamentals of packaging technology (5th ed.). Institute of Packaging Professionals. ISBN: 978-1-930268-37-2 Twede, D., & Goddard, R. (2021). Cartons, crates and corrugated board: Handbook of paper and wood packaging technology (2nd ed.). DEStech Publications. ISBN: 978-1-60595-120-5 (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 Folding Cartons Facebook Twitter LinkedIn Pinterest Relevant Posts