How to Engineer Corrugated Packaging for Automation

Why Custom Corrugated Boxes Remain a 2026 Essential Custom corrugated boxes continue to be the most relied-on packaging solution for industries ranging from industrial manufacturing to ecommerce. But in 2026, the focus is shifting from basic box customization to engineered performance, material precision, and automation-ready design. Buyers are no longer just sourcing packaging—they’re optimizing it for speed, cost, and product protection. Whether you’re buying corrugated boxes for shipping, retail display, or product kitting, here’s what to expect this year. Structural Design Is Driving the New Definition of Custom In 2026, “custom corrugated packaging” means more than just size and print—it’s about functional structure. Businesses are prioritizing right-size engineering to cut down on void fill, improve stacking, and reduce damage Popular designs like multi-depth RSCs, auto-lock bottoms, and dual-SKU shipper trays are growing Custom inserts and internal supports are being integrated into the box structure itself—not as separate packaging steps If you’re shipping high-value or odd-shaped products, expect 2026 solutions to emphasize built-in protection and packaging efficiency. Corrugated Material Selection Is More Technical Than Ever Rising board costs and stricter sustainability requirements are reshaping how materials are specified. Clients are now choosing corrugated by ECT, puncture rating, and flute profile, not just by thickness Recycled and virgin content blends are being optimized based on weight, moisture exposure, and destination Lighter-weight corrugated is being reinforced through design (edge wraps, folded ribs, etc.), not just thicker walls This year, your corrugated box’s performance will come more from material science + structure than brute strength. Automation Compatibility Is a Procurement Priority Packaging that doesn’t run smoothly on automated lines is a liability. In 2026: Buyers are demanding machine-compatible corrugated formats, with tolerances that support automated erecting, loading, and sealing Expect growth in auto-bottom boxes, precise glue flap alignment, and barcode-friendly panel design Custom boxes are being designed in tandem with fulfillment processes—not retrofitted afterward For high-volume shippers, compatibility with WMS and automation systems is now a core spec—not an afterthought. Custom Corrugated Boxes Are Becoming Data-Driven Sustainability Tools 2026 sustainability goals are technical, not theoretical. Corrugated boxes are being selected for FSC or SFI certification, recyclability scores, and regional sourcing proximity Life cycle assessment (LCA) data is being requested by major retailers and procurement teams Minimalist branding, lighter flutes, and efficient structural design are all being used to cut carbon, not just cost Sustainability is part of how your box is measured—so make sure it’s part of how it’s designed. Built-In Branding, Not Just Printed Logos While most custom corrugated boxes—especially RSC formats—still use single-color flexo print, more are evolving to support multi-SKU visibility, inventory control, and regulated handling. Expect wider use of label panels, QR codes, and internal printing for ease of returns and fulfillment High-end retail corrugated (especially for appliances or electronics) will see more use of digital or lithographic labels Structural design now plays a role in branding—form, function, and fit are part of how buyers perceive value Your corrugated box is part of the product experience, even if it’s headed for a warehouse—not a retail shelf. Conclusion: Corrugated in 2026 Is a Strategic Advantage If you’re still buying boxes by the spec sheet, you’re missing opportunities to improve speed, reduce damage, and increase operational efficiency. In 2026, custom corrugated boxes are no longer just a container—they’re part of your business infrastructure. Whether you’re focused on industrial logistics, subscription fulfillment, or protecting high-value goods, now is the time to reassess your packaging. Brown Packaging helps brands design fully customized corrugated solutions that align with your cost targets, sustainability goals, and logistics requirements. (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 pads are an essential component of the packaging industry. They are versatile, durable, and cost-effective solutions for a wide range of packaging needs. Corrugated pads can be used for both cushioning and separating products during transport or storage. In this ultimate guide to corrugated pads, we will explore everything you need to know about these valuable packaging materials. What are Corrugated Pads? Corrugated pads are flat pieces of corrugated cardboard that are used for cushioning and separating products during transport or storage. They are made by sandwiching a layer of fluted cardboard between two layers of linerboard. The fluted layer gives the pad its strength and cushioning properties, while the linerboard provides a smooth surface for printing and labeling. There are two main types of corrugated pads: single-wall and double-wall. Single-wall corrugated pads have one layer of fluting sandwiched between two layers of linerboard, while double-wall corrugated pads have two layers of fluting sandwiched between three layers of linerboard. Double-wall corrugated pads are more durable and provide better cushioning properties than single-wall corrugated pads. Advantages of Using Corrugated Pads Corrugated pads offer many advantages over other packaging materials. Here are some of the benefits of using corrugated pads in packaging: Cost-effectiveness: Corrugated pads are an affordable packaging solution that provides excellent value for money. They are cheaper than other materials such as plastic, foam, or wood. Versatility: Corrugated pads can be used for a wide range of packaging needs, from protecting fragile items during transport to separating and organizing products during storage. Environmental sustainability: Corrugated pads are made from renewable materials, and they are 100% recyclable. They have a lower carbon footprint than other packaging materials, and they do not contribute to landfill waste. Customizability: Corrugated pads can be customized to meet specific packaging needs. They can be cut to any size or shape, printed with branding or labeling, and even laminated for added strength and durability. Applications of Corrugated Pads Corrugated pads are used in many different industries and businesses. Here are some of the common uses of corrugated pads in packaging: Transportation and logistics: Corrugated pads are used to protect products during transport, especially fragile or delicate items such as electronics, glassware, or ceramics. Manufacturing and distribution: Corrugated pads are used to separate and organize products during manufacturing and distribution. They are often used in automated assembly lines to prevent damage or scratching of products. Retail packaging: Corrugated pads are used in retail packaging to provide cushioning and support for products. They are commonly used in shipping boxes or retail displays. Food packaging: Corrugated pads are used in food packaging to separate and cushion products such as eggs, fruits, and vegetables. They are also used in shipping boxes for food and beverage products such as wine bottles or canned goods. Innovative applications of corrugated pads in packaging include using them as insulation for homes, creating furniture, and even building temporary structures such as emergency shelters. Choosing the Right Corrugated Pad for Your Packaging Needs When choosing a corrugated pad for your packaging needs, there are several factors to consider. Here are some tips for choosing the right corrugated pad: Product weight and fragility: The weight and fragility of the product you are packaging will determine the thickness and strength of the corrugated pad you need. Heavier or more fragile items require thicker or double-wall corrugated pads. Shipping and storage conditions: The shipping and storage conditions of your product will also affect the type of corrugated pad you need. For example, if your product is being shipped long distances, you may need a stronger corrugated pad to withstand the vibrations and impact of transportation. Customization options: Corrugated pads can be customized to meet specific packaging needs. Consider whether you need a custom size or shape, printing or labeling, or laminated options for added strength. Tips for Using Corrugated Pads Effectively To maximize the protective properties of corrugated pads, here are some best practices for using them effectively: Proper placement: Place corrugated pads between products to prevent scratching or damage during transport or storage. Multiple layers: For heavier or more fragile items, consider using multiple layers of corrugated pads for added protection. Cushioning: Use additional cushioning materials such as bubble wrap or foam inserts to provide extra protection for fragile items. Storage and handling: Store corrugated pads in a dry, cool area to prevent moisture damage. Handle them carefully to avoid creases or tears that could reduce their effectiveness. If you are interested in corrugated pads, 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. Corrugated Pads Facebook Twitter LinkedIn Pinterest Relevant Posts

Corrugated bin boxes have become a staple in the retail industry, offering a myriad of benefits for both store owners and shoppers alike. At first glance, they might seem like ordinary brown boxes, but a deeper dive reveals the genius behind their design and utility. In this blog post, we’ll delve into the reasons why these boxes are so popular in retail. Strength and Durability Cost-Effective Sustainable and Eco-friendly Flexibility In Storage Enhance Product Visibility Branding and Customization Protection from Damage Easy to Assemble and Disassemble Strength and Durability Corrugated bin boxes are designed with a fluted, wavy layer sandwiched between two flat liners. This unique structure provides an added layer of strength, making them more resilient than their plain cardboard counterparts. As such, they can withstand the pressures of stacking and the general wear-and-tear of a busy retail environment. Cost-Effective Retail businesses, especially those with tight margins, are always on the lookout for ways to save money. Corrugated bin boxes provide a cost-effective storage solution. They are often cheaper than plastic or metal alternatives, yet offer comparable durability and strength. Sustainable and Eco-Friendly With the growing emphasis on sustainability in today’s world, businesses are keen to showcase their eco-friendly practices. Corrugated bin boxes are recyclable, and many are made from recycled materials. By using these boxes, retailers can reduce their carbon footprint and promote a more sustainable business model. Flexibility in Storage These boxes come in a wide range of sizes, making them suitable for storing various products, from small accessories to larger goods. They can be customized to fit the specific needs of a retailer, ensuring that space is used efficiently. Furthermore, their modular design makes it easy to adjust display setups as inventory or promotions change. Enhanced Product Visibility Many corrugated bin boxes have an open-front design. This allows customers to quickly glance and see the products contained within, promoting impulse purchases. For retailers, it’s an opportunity to display products in an organized and appealing manner, increasing the likelihood of sales. Branding and Customization Corrugated bin boxes can be customized to reflect a retailer’s brand image. With the option of adding logos, colors, and designs, retailers can make these boxes an extension of their brand identity. This not only promotes brand consistency but also makes the shopping experience more immersive for customers. Protection from Damage The fluted design of corrugated boxes offers a cushioning effect. This protects the products inside from potential damage due to impacts or vibrations. For fragile items or those that need a little extra care, these boxes can be a godsend. Easy to Assemble and Disassemble Most corrugated bin boxes come flat-packed, making them easy to transport and store when not in use. Assembling them is often a straightforward process, requiring no tools. This ease of use can save time and effort, especially for retailers with frequently changing displays. Conclusion The reasons detailed above highlight the multiple advantages that corrugated bin boxes bring to the retail sector. They are not just practical storage solutions, but also vehicles for branding, promoting sustainability, and enhancing the overall shopping experience. As the retail landscape continues to evolve, the humble corrugated bin box stands out as an indispensable tool in the toolkit of successful retailers. If you are interested in corrugated bin boxes, then partner with Brown Packaging today to get started. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce Design Foam Folding Carton Packaging Plastic Packaging Pouch Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Corrugated Bin Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts