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 FormatsRSC 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 DepthsMaintain 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 ConsistencyBoxes 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 FeaturesIf 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 GradesBoards with better stiffness (e.g., 44 ECT or 275#) maintain shape during pick-and-place and resist deformation in automated erecting. ✔ Use Coatings Where NeededFor packaging that passes through friction belts or vacuum suction, a clay-coated or high-slip surface may improve feed reliability. ✔ Avoid WarpPoor 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 RegistrationAutomation 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 ThoughtsCorrugated 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. (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

Why Board Grade Selection Matters In today’s volatile supply chain environment, packaging failures aren’t just a nuisance—they’re a liability. Damage in transit, product returns, and load instability all lead back to one foundational element: board grade. Whether you’re shipping across the country or staging products for long-term storage, the right corrugated board strength directly impacts product integrity, compliance, and bottom-line efficiency. Understanding Board Grade Classifications Corrugated board grade is defined by its burst strength (measured in pounds), edge crush test (ECT) rating, or basis weight in pounds per 1,000 square feet. The two most common standards: Mullen Test (Burst Strength): Measures resistance to puncture or rupture under pressure (e.g., 200#). Edge Crush Test (ECT): Measures stacking strength and compression resistance along the edge (e.g., 32 ECT). Higher board grades offer greater durability but come at a cost—so matching board performance to supply chain risk is key. How Board Grade Supports Supply Chain Resilience ✔ Reduces Transit DamageHeavier board grades (like 44 ECT or 275#) are essential for heavier items or mixed-pallet shipping. They prevent crushing under load and protect high-value products from collapse or impact. ✔ Improves Stacking StabilityIf your supply chain includes warehousing, transloading, or racking, poor stacking strength leads to bottom-box failures. ECT-rated boxes offer predictable stacking loads, enabling more reliable palletization strategies. ✔ Adapts to Environmental StressorsIn humid or high-temperature zones, lower-quality board can warp or delaminate. Upgrading to moisture-resistant coatings or wax-treated grades extends package integrity in unpredictable conditions. ✔ Meets Carrier and Retailer ComplianceMajor carriers and retailers (e.g., Amazon, Walmart) often require packaging that meets minimum board grade thresholds for specific product categories. Failing to comply can result in chargebacks or denied loads. Matching Board Grade to Application Lightweight Goods (<30 lbs): 32 ECT or 200# is often sufficient for controlled distribution. Midweight/Stacked Goods (30–65 lbs): 44 ECT or 275# single-wall offers better stability. Heavy or Fragile Items: 48 ECT+, 350# double-wall, or even triple-wall is standard for machinery, appliances, or multi-SKU master packs. Export Shipments: Double-wall with moisture resistance is critical for sea containers and extended transit. Why Resilience Now Means Cost Efficiency Later Skimping on board grade may reduce material costs short-term, but it increases risks throughout the supply chain: Higher damage rates Increased return logistics More manual rework at DCs Lower pallet efficiency By engineering packaging with the right board spec, brands can build flexibility into distribution—whether absorbing shock during LTL shipping or maintaining load stability during storage. Final Thoughts Your corrugated board grade isn’t just a spec—it’s a strategic decision that drives supply chain resilience. From minimizing product loss to meeting compliance and stacking standards, choosing the right board means fewer disruptions and greater operational continuity. At Brown Packaging, we help businesses select, test, and implement the right corrugated materials based on real-world demands. (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