How to Engineer Corrugated Packaging for Automation
Why Packaging Automation Compatibility Matters
As more fulfillment centers, contract packagers, and manufacturers turn to automation, packaging that isn’t compatible with machinery becomes a costly bottleneck. From misfeeds on case erectors to jams in packing stations, poorly designed corrugated boxes slow down operations, increase error rates, and limit throughput. For high-volume brands and logistics operations, automation-compatible packaging isn’t optional—it’s a core part of the system.
Common Points of Failure with Corrugated in Automation Systems
Automation often fails not because the equipment is faulty, but because the packaging isn’t designed for machine handling. Common issues include:
- Poor dimensional tolerance: If the box flaps don’t align cleanly, case erectors and tapers will jam.
- Low board rigidity: Boxes made from lightweight corrugated collapse during suction or robotic pick-and-place.
- Inconsistent slotting and scoring: Uneven folds confuse sensors or result in skewed box geometry.
- Incompatible closure style: Designs like auto-lock bottoms or complex folds may not be machine-erectable.
Structural Design Principles for Automation Compatibility
✔ Stick to Clean, Repeatable Formats
RSC and FOL boxes with precision scoring are ideal for case erectors and tapers. Avoid overly intricate die cuts or asymmetrical flaps unless they’re downstream of automation.
✔ Use Consistent Die-Lines and Slot Depths
Maintain tight tolerances on slot depth, flap width, and glue tabs. Variability in cutting leads to misfeeds on erectors or case packers.
✔ Right-Size the Box for Consistency
Boxes should hold contents securely with minimal void fill. Automated packout systems are most efficient when the box requires no manual fitting or adjustment.
✔ Add Automation-Friendly Features
If machine-packing is in use, design inserts or partitions that can be preloaded or nested without human intervention. Consistent entry points and fitment are key.
Material Considerations
✔ Choose Higher Rigidity Board Grades
Boards with better stiffness (e.g., 44 ECT or 275#) maintain shape during pick-and-place and resist deformation in automated erecting.
✔ Use Coatings Where Needed
For packaging that passes through friction belts or vacuum suction, a clay-coated or high-slip surface may improve feed reliability.
✔ Avoid Warp
Poor storage conditions or low-quality material lead to box warp, which ruins automation compatibility. Store flat and dry, and use high-quality stock.
Don’t Forget Print Registration
Automation often uses machine vision to scan barcodes or orientation markers. Digital or flexo-printed registration cues must be in consistent locations, with sharp contrast and no ink bleed. Variable data printing can also assist with lot tracking in automated pick-pack systems.
Benefits of Automation-Compatible Corrugated
- Faster throughput with fewer jams or stoppages
- Lower labor costs due to minimal hand correction
- Better reliability in high-speed fulfillment environments
- Scalability when expanding SKUs or entering new distribution channels
Final Thoughts
Corrugated packaging isn’t just a vessel—it’s a mechanical component in an automated system. Brands that optimize their box design, material spec, and print layout for automation reduce errors, increase efficiency, and lower cost per shipment. If you’re designing packaging for automation or reworking a manual process, Brown Packaging can help engineer corrugated solutions that perform in real-world fulfillment lines.
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When it comes to packaging solutions, corrugated boxes are at the forefront of industry choices, providing durability, flexibility, and sustainability. However, the debate often arises between using kraft or white corrugated material. Both options have their unique benefits and considerations. Here’s a detailed comparison to guide you in making the right choice for your packaging needs. Aesthetic Appeal White Corrugated Material: White corrugated boxes offer a clean, crisp appearance that’s perfect for showcasing high-resolution graphics and detailed print. Their smooth surface is ideal for businesses looking to present a polished and premium image to their customers. Great for retail packaging, especially for electronic items, cosmetics, and luxury goods. Kraft Corrugated Material: The natural brown hue of kraft corrugated boxes gives them a rustic, organic feel. This is a favorite for brands aiming for an eco-friendly or artisanal image. They don’t present graphics as vibrantly as white boxes, but they carry a charm of their own. Printing and Branding White Corrugated Material: The white background serves as a blank canvas, ensuring that colors stand out vibrantly and true to their original hue. This is essential for brands with specific color palettes and detailed branding requirements. Kraft Corrugated Material: The brownish tone of kraft corrugated material can influence the appearance of printed colors. While this might not be ideal for brands requiring precise color matching, it works well for those aiming for a natural or vintage aesthetic. Plus, minimalistic designs with black or darker hues often pop beautifully on kraft. Environmental Considerations White Corrugated Material: The bleaching process used to achieve the white color can have environmental implications. However, many suppliers now offer white corrugated material made from recycled fibers or with eco-friendly bleaching alternatives. Kraft Corrugated Material: Typically more eco-friendly, kraft corrugated boxes are often made from unbleached paper pulp. The absence of the bleaching process means fewer chemicals are involved, making them a more sustainable choice for environmentally-conscious businesses. Cost White Corrugated Material: Generally, white corrugated boxes tend to be slightly more expensive than their kraft counterparts, due to the additional processing required to achieve their pristine appearance. Kraft Corrugated Material: Being less processed, kraft corrugated material usually comes with a lower price tag, making them a cost-effective choice for bulk packaging needs. Durability Both kraft and white corrugated materials offer excellent durability and protection, depending on their flute size and wall construction. However, any perceived difference in strength between the two is more about the construction and thickness of the corrugated box rather than the color or type of paper used. Market Perception White Corrugated Material: Often associated with a higher-end market perception, white boxes can elevate a product’s perceived value. Kraft Corrugated Material: Kraft boxes exude an earthy, organic vibe and are often associated with sustainability and eco-friendliness, making them a favorite for green and artisanal brands. Final Thoughts When deciding between kraft and white corrugated materials, it’s essential to consider your brand’s image, budget, and environmental stance. If you’re aiming for a high-end, polished appearance with vibrant printing, white corrugated material is your best bet. On the other hand, if you want to exude a natural, eco-friendly vibe with cost-effectiveness, kraft is the way to go. Remember, the choice between kraft and white isn’t just about aesthetics or cost – it’s about aligning the packaging with your brand’s values and message. Whichever you choose, ensure it resonates with your target audience and serves your product’s needs effectively. If you are interested in corrugated boxes, 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
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Structurally designing your corrugated box involves understanding the specific requirements of your product and applying principles of material science and engineering to ensure optimal protection, efficiency, and cost-effectiveness. This process requires careful consideration of the box’s dimensions, material grade, flute type, and the intended use to create a packaging solution that meets both logistical and aesthetic needs. Understanding the Basics of Corrugated Boxes Before diving into the design process, it’s important to grasp the fundamental components of a corrugated box: Fluting: The wavy layer of corrugated paper that provides cushioning and strength. The size, type and the material of the flute affect the box’s compression strength, stacking strength, and crush resistance. Linerboards: Flat sheets of paper that sandwich the fluting, contributing to the box’s durability and structural integrity. Box Types: Common configurations include the Regular Slotted Container (RSC), Full Overlap (FOL), and Die-Cut designs, each offering different benefits in terms of protection and assembly efficiency. Step 1: Assess Product Requirements Start by evaluating the weight, dimensions, and fragility of the product. Consider any additional space needed for internal packaging materials like bubble wrap or foam inserts, which provide extra protection for delicate items. This assessment will guide the choice of box size and strength needed to ensure safe transport and storage. Step 2: Select Material and Flute Type Choose the appropriate material grade and flute type based on the product’s weight and the level of protection required. For lightweight items, a single-wall box with smaller flutes like B or C may suffice. Heavier or more fragile items may require double-wall or triple-wall boxes with larger flutes like A or BC for increased cushioning and strength. The Edge Crush Test (ECT) rating of the cardboard is a critical factor here, indicating the box’s ability to withstand external pressures. Step 3: Design for Efficiency and Sustainability Efficiency in packaging not only reduces material costs but also minimizes waste, contributing to sustainability. Design your box to fit your product snugly while allowing for minimal extra packaging material. Consider using recyclable materials and designing for ease of recycling after use, such as avoiding mixed materials that are difficult to separate. Step 4: Prototype and Test Once the initial design is established, create a prototype of your box. This allows for hands-on testing to ensure the box meets your requirements in terms of size, strength, and functionality. Conduct tests that mimic real-world handling, shipping, and stacking scenarios to identify any structural weaknesses or design flaws. Step 5: Customization and Branding Customization isn’t just about aesthetics; it can also enhance the box’s structural integrity. For example, die-cut inserts not only secure products within the box but also add rigidity to the structure. Use the exterior for branding, but ensure that any printing or customization does not compromise the box’s strength. Step 6: Iterate Based on Feedback Use feedback from the testing phase to refine your design. This may involve adjusting dimensions, changing the flute type, or reevaluating the material grade. Iteration is a crucial step in optimizing the design for both protection and cost. Conclusion Structurally designing a corrugated box is a detailed process that blends science, engineering, and aesthetics. It requires a deep understanding of the product needs, material properties, and the logistical demands of shipping and handling. By following these steps and focusing on both function and form, you can develop a corrugated box that not only protects your product but also enhances your brand’s presentation and sustainability efforts. If you are interested in custom structurally designed corrugated boxes, 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