Understanding Corrugated Board: Single Wall, Double Wall, and Triple Wall Packaging
When it comes to packaging, boxes made from a material called corrugated board are among the most commonly used types today. Corrugated board consists of a fluted sheet sandwiched between two flat sheets of paperboard. This type of board is available in different grades and thicknesses, and is classified into three types: single wall, double wall, and triple wall.
Single Wall Board
Single wall board is the most basic type of corrugated board, consisting of a single layer of fluted paperboard sandwiched between two flat sheets of paperboard. Single wall board is available in different grades and thicknesses, and is ideal for packaging applications that require a lightweight and cost-effective solution. It is often used for shipping and storing small items such as books, clothing, and electronics, as well as for product displays, storage bins, and mailers.
Double Wall Board
Double wall board is made by combining two layers of fluted paperboard with three flat sheets of paperboard. This type of board is thicker and more durable than single wall board, and is ideal for packaging applications that require extra protection and strength. It is often used for shipping and storing heavier items such as appliances, furniture, and automotive parts, as well as for industrial packaging, retail displays, and point-of-purchase displays.
Triple Wall Board
Triple wall board is the thickest and strongest type of corrugated board, made by combining three layers of fluted paperboard with four flat sheets of paperboard. This type of board is ideal for packaging applications that require maximum protection and strength. It is often used for shipping and storing extremely heavy items such as machinery, equipment, and bulk products, as well as for pallet boxes, crates, and reusable containers.
Choosing the Right Type of Board
When choosing the type of board for packaging, factors such as the weight and size of the product being shipped or stored, the shipping and handling conditions, and the intended use of the packaging should be considered. Single wall board is suitable for smaller and lighter items, while double wall or triple wall board is necessary for heavier and larger items that require extra protection and strength. For products that require maximum protection against shock, vibration, and impact, triple wall board is the best choice.
Summary: Corrugated Boards Explained
In conclusion, corrugated board is a versatile packaging material that offers various options for different packaging needs. By selecting the right type of board, businesses can ensure that their products are properly protected during transportation and storage.
If you are interested in any stock or custom corrugated packaging, then partner with Brown Packaging today to get started.
In 2026, sustainability is no longer just a trend—it’s a buyer expectation. Forest Stewardship Council (FSC) certification has become a key benchmark for responsible packaging, signaling that materials are sourced from responsibly managed forests. For packaging buyers, FSC certification is more than a compliance checkbox—it’s a brand value that influences purchasing decisions, retailer acceptance, and customer loyalty. What Is FSC Certification? The Forest Stewardship Council certifies that paper-based packaging materials are sourced from forests managed for environmental responsibility, social benefit, and economic viability. FSC Mix: Packaging contains a blend of FSC-certified and controlled wood. FSC Recycled: Packaging is made entirely from recycled fiber. FSC 100%: Packaging is sourced only from FSC-certified forests. Why FSC Matters to Buyers in 2026 Retail access: Many major retailers now require FSC-certified packaging. Sustainability goals: Aligns with corporate ESG and carbon reduction commitments. Consumer trust: Customers recognize the FSC label and view it as credible. Global compliance: Meets international sustainability regulations. How FSC Certification Strengthens Brand Value Differentiation: Stand out with certified sustainable packaging. Marketing advantage: FSC logos reinforce eco-friendly messaging. Risk reduction: Verified sourcing prevents greenwashing claims. Customer loyalty: Environmentally conscious buyers prefer certified products. Challenges in FSC Implementation Limited supply of certain FSC substrates. Higher costs compared to non-certified materials. Need for supplier audits and documentation. Packaging Solutions with Brown Packaging Brown Packaging partners with buyers to integrate FSC-certified materials into corrugated boxes, folding cartons, and retail packaging. Our solutions support sustainability while maintaining cost efficiency and protection. Contact us to strengthen your brand with FSC-certified packaging. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Consumer Insights on Sustainable Packaging. 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: Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Sustainable Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Sustainability is now a top priority for packaging buyers. Retailers, regulators, and consumers are all demanding packaging solutions that reduce environmental impact without sacrificing performance. In 2026, buyers must balance eco-friendly materials, cost, and compliance to build programs that are both effective and future-ready. What Buyers Need to Know About Sustainable Packaging Regulatory pressure: Governments are enforcing stricter rules on recyclability and plastic use. Retail mandates: FSC certification and recyclable packaging are becoming standard requirements. Consumer expectations: Customers increasingly choose brands with visible sustainability commitments. Sustainable Material Options Recycled corrugated: High recycled content while maintaining compression strength. Compostable films: Suitable for select food and retail applications. Molded pulp inserts: Replace foam or plastic for protective packaging. Water-based coatings: Enhance moisture resistance without harmful chemicals. Balancing Cost and Performance Right-size packaging: Reduces material waste and shipping costs. Hybrid solutions: Combine eco-materials with corrugated for balance. Life cycle analysis: Evaluate true environmental impact, not just marketing claims. How to Evaluate Sustainable Suppliers Verify FSC, SPC, or ISO certifications. Request testing data for durability and recyclability. Audit supply chains for consistency and transparency. Ensure claims meet local and international compliance standards. Packaging Solutions with Brown Packaging Brown Packaging helps buyers implement sustainable packaging programs that balance cost, performance, and compliance. From recycled corrugated to eco-friendly coatings and inserts, we deliver solutions that meet 2026 sustainability goals. Contact us to explore sustainable packaging options. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Packaging Sustainability Trends and Buyer 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. Sustainable Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Choosing the right packaging material is one of the most important decisions buyers face. Single-material packaging offers simplicity and recyclability, while multi-material designs provide enhanced performance and protection. Understanding the trade-offs helps companies balance cost, functionality, and sustainability goals in 2026. What Is Single-Material Packaging? Single-material packaging uses one substrate—such as corrugated board, folding carton, or plastic—for the entire structure. Advantages: Easier to recycle and dispose. Lower material costs in many cases. Streamlined sourcing and inventory. Supports sustainability messaging. Disadvantages: Limited barrier protection. Less customization for fragile or complex products. May require added thickness for strength, increasing weight. What Is Multi-Material Packaging? Multi-material packaging combines two or more substrates—such as corrugated with foam, or paperboard laminated with film—to achieve specific performance outcomes. Advantages: Greater protection against moisture, oxygen, and impact. Allows for premium finishes and enhanced graphics. Ideal for fragile or high-value products. Customizable for unique supply chain conditions. Disadvantages: More difficult to recycle due to material separation. Higher cost and longer lead times. Complex sourcing and inventory management. When to Use Each Approach Single-material packaging: Best for products with low fragility, strong sustainability requirements, or cost-driven programs. Multi-material packaging: Best for high-value, fragile, or regulated products requiring advanced protection. Balancing Performance and Sustainability Buyers must weigh performance needs against eco goals: Use recyclable coatings to extend single-material performance. Choose hybrid designs that separate easily for recycling. Apply multi-material solutions only where risk of damage outweighs cost. Packaging Solutions with Brown Packaging Brown Packaging helps buyers evaluate when to use single- vs. multi-material packaging. Our team balances sustainability, performance, and cost to deliver solutions tailored to your supply chain. Contact us to explore the right approach for your products. References Forest Stewardship Council (FSC). (2023). FSC Packaging Certification Guidelines. Retrieved from https://fsc.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.Sustainable Packaging Coalition. (2022). Design for Recyclability and Multi-Material Packaging 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
One of the biggest challenges in sustainable packaging is balancing environmental responsibility with product protection. Buyers often worry that switching to eco-friendly materials means sacrificing durability or driving up costs. In 2026, new material technologies allow brands to meet sustainability goals without compromising strength or supply chain performance. Why Protection Still Matters Damaged products create more waste than packaging ever could. Returns increase logistics costs and carbon emissions. Retailers and e-commerce platforms expect packaging to deliver both sustainability and reliability. Eco-Friendly Material Options Recycled corrugated: Maintains stacking strength while reducing virgin fiber use. Molded pulp inserts: Cushion fragile items while replacing plastic foam. Water-based barrier coatings: Add moisture resistance without plastic films. Compostable films: Ideal for short shelf-life or single-use applications. Paper-based mailers: Replace poly mailers for e-commerce shipments. How to Balance Eco Goals and Protection Use right-sizing to reduce material volume while improving fit. Apply hybrid solutions (corrugated + pulp) for high-value goods. Conduct ISTA testing to validate protective performance. Match material choice to product fragility and supply chain conditions. Examples in Action Electronics: Molded pulp trays replacing EPS foam. Food and beverage: FSC-certified corrugated with recyclable coatings. Retail e-commerce: Recycled paper mailers protecting apparel. Packaging Solutions with Brown Packaging Brown Packaging develops eco-friendly solutions that protect products while meeting sustainability requirements. From recycled corrugated to innovative coatings, our team ensures you never trade protection for environmental impact. Contact us to explore eco-material options. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Eco-Friendly Packaging Materials and Case Studies. Retrieved from https://sustainablepackaging.orgASTM International. (2023). ASTM D4169: Standard Practice for Performance Testing of Shipping Containers and Systems. (714)300-0650 request@brownpackaging.com Most Recent Posts: 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
In today’s competitive market, packaging affordability doesn’t start with cheaper materials — it starts with smarter design. Every score, fold, and insert decision affects not only how a box looks and feels, but how efficiently it’s made, shipped, and used. Structural engineering is the silent driver of cost efficiency — optimizing strength, space, and performance before the first sheet is ever printed. Why Structure Matters More Than You Think The most impactful cost savings in packaging rarely come from supplier discounts; they come from structural efficiency.A box that uses 10% less board but maintains the same compression strength directly reduces both material and freight cost. A redesigned insert that eliminates the need for secondary packaging saves time and labor at the line. Every cut line and fold path tells a story of cost, sustainability, and brand care — and when those align, affordability becomes part of your brand’s DNA. Designing for Efficiency, Not Excess In a market saturated with overbuilt packaging, engineering restraint is a competitive advantage. Structural teams now rely on 3D CAD modeling and virtual prototyping to simulate performance before production — identifying unnecessary material use and structural redundancies. Through precision die-line planning, engineers can improve sheet yield, reduce assembly time, and minimize void space — the dead air that drives up freight bills.It’s not about doing less; it’s about doing smarter. Balancing Protection and Presentation The temptation to “overprotect” products is common — especially in fragile or high-value goods. But protection doesn’t have to mean bulk. Strategic reinforcements, engineered fluting, and interlocking designs can maintain crush resistance and shock absorption while reducing total board weight. For e-commerce and shelf packaging alike, brands can achieve premium presentation with structural simplicity — a key to making packaging both sustainable and affordable. Prototyping to Prevent Waste Prototyping isn’t just for aesthetics — it’s a safeguard against costly production errors.With short-run sample testing and performance mockups, brands can evaluate fit, function, and protection early in development. Adjusting dimensions by fractions of an inch can save thousands in material waste and prevent rejected runs down the line. Smart packaging buyers now view prototyping not as an expense, but as a cost-control strategy that pays dividends in scale. How Structural Design Supports Brand and Budget Affordable design doesn’t mean compromising brand identity — it means integrating brand goals into structure. A well-engineered box reinforces trust, ensures product consistency, and communicates value through precision and fit. When structure, design, and production align, packaging stops being a cost and starts becoming a business asset. That’s where the real savings live — and where long-term brand equity begins. The Brown Packaging Difference At Brown Packaging, every packaging solution starts with structural intent — not guesswork.Our engineering and design teams collaborate to create packaging that performs across shipping, retail, and automation lines, balancing protection, brand visibility, and cost efficiency. We don’t cut corners; we cut waste.That’s how our clients achieve packaging that’s not just affordable — it’s engineered to perform. References Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. PMMI. (2024). Optimizing Structural Design for Packaging Efficiency. Packaging World. (2025). Engineering the Future of Cost-Effective Packaging. Smithers. (2025). Packaging Innovation and Material Efficiency Trends. (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
Every brand is feeling the squeeze — higher raw material costs, volatile freight rates, and a consumer base more price-conscious than ever. But cutting packaging budgets blindly can lead to damaged goods, compliance issues, and eroded brand value. Smart brands aren’t chasing cheaper boxes — they’re making smarter packaging decisions that balance performance, cost, and perception. The difference between saving money and losing value comes down to how you evaluate your packaging, not just what you pay for it. Beyond Unit Price: Understanding Total Packaging Cost A low unit price might look great on paper — until you factor in assembly time, damage rates, and freight efficiency. Smart packaging evaluation considers the total cost of ownership, including: Material yield (how efficiently sheets convert into boxes) Pallet and trailer utilization (freight optimization) Labor efficiency (ease of assembly or automation compatibility) Product protection (damage rates, replacements, and returns) When buyers assess all these metrics, the lowest-cost box often isn’t the best-value box. Material Selection That Saves in the Long Run Switching materials isn’t just about cutting cost — it’s about reducing waste and improving performance. For instance, moving from double-wall to a high-performance single-wall with better flute structure can cut weight and shipping cost without sacrificing protection. In folding cartons, substrate optimization — using a lighter caliper SBS or switching to coated recycled board — can yield savings that scale across production runs. And for rigid boxes, structural tweaks like thinner chipboard paired with strong wrap papers can preserve presentation while reducing material use. Every small change adds up when you scale across thousands of units. Design Efficiency: The Overlooked Cost Saver A smart structural design can eliminate cost before production even starts. Simplifying folds, reducing glue flaps, or reengineering inserts can cut assembly time and material waste. Modern packaging engineers use CAD-based dieline analysis to optimize layouts — ensuring maximum sheet yield and minimal offcut. For e-commerce and retail brands alike, right-sizing packaging improves shipping efficiency and reduces filler materials while maintaining the brand’s polished look. It’s not just design — it’s design that earns its keep Printing Smart: Matching the Process to the Purpose Not every job needs premium litho or complex spot varnishes. A good packaging partner matches print method to scale and brand intent: Flexo printing for high-volume, cost-efficient runs. Digital printing for short runs, personalization, and multi-SKU campaigns. Litho laminating for high-end visuals in rigid or premium retail displays. By choosing the right print method early, brands can avoid over-engineering — saving both time and money without compromising quality. Data-Driven Decisions: The New Standard for Packaging Buyers Leading companies now use data to guide packaging spend. Damage rate metrics, SKU-level freight analysis, and consumer perception studies all contribute to smarter choices. Smart buyers are no longer asking, “What’s the cheapest box?” They’re asking, “What’s the most efficient box that protects the product, ships well, and supports brand goals?” This mindset shift is what separates cost-cutting from cost control. The Brown Packaging Approach At Brown Packaging, we help brands make smarter packaging decisions by combining engineering analysis, supplier network leverage, and real-world testing. Our process aligns packaging performance with total cost goals — from box design to print selection and logistics. The result: stronger packaging, lower waste, and sustainable cost savings that scale with your business. Because in today’s market, smart packaging isn’t just a cost center — it’s a competitive advantage. References PMMI. (2025). Operational Cost Efficiency in Packaging and Logistics. McKinsey & Company. (2024). Total Cost of Ownership in Consumer Goods Packaging. Packaging World. (2025). Data-Driven Decisions in Packaging Sourcing. Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). (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
By submitting your information, you agree to our terms and conditions and privacy policy.
The terms cardboard and corrugated are often used interchangeably, but in packaging, they mean very different things. Cardboard is a catch-all term used by consumers, while corrugated and chipboard each have specific material definitions and applications. Knowing the difference helps buyers choose the right packaging solution and avoid costly mistakes. Corrugated: Material and Products Corrugated material is built from at least three layers: an inside liner, an outside liner, and a fluted medium in between. Additional layers can be added to improve compression and stacking strength. This structure makes corrugated ideal for protective and high-strength packaging. Products Made with Corrugated Boxes (RSC, FOL, die-cut mailers, etc.) POP displays Dividers and partitions Edge protectors Sheets and inserts Corrugated is available in natural kraft brown or bleached white. The brown color often leads consumers to mistakenly call it “cardboard.” Chipboard: Material and Products Chipboard (sometimes called paperboard) is manufactured by pressing small wood particles with resin under heat and pressure to form a smooth, rigid sheet. While it is lightweight and inexpensive, it does not provide the same compression or stacking strength as corrugated. Products Made with Chipboard Folding cartons for small, lightweight goods Dividers and partitions Inserts and sleeves Chipboard is commonly used in retail-ready cartons for cereal, cosmetics, and lightweight consumer goods. Like corrugated, it typically appears in white or brown, reinforcing the consumer misuse of the word “cardboard.” Why the Difference Matters Using the wrong material for packaging can affect cost, product safety, and supply chain efficiency. For example: Corrugated is essential when structural strength and stacking are required (shipping boxes, displays, bulk distribution). Chipboard works when lightweight retail packaging is sufficient (folding cartons, retail sleeves). Referring to corrugated as “cardboard” may cause confusion when sourcing from suppliers who distinguish between the two. Selecting the right supplier also matters — not all packaging providers manufacture or stock both corrugated and chipboard. Working with one that does ensures consistent quality, efficiency, and fewer inventory issues. Corrugated Box Folding Carton (Chipboard) Work With Brown Packaging At Brown Packaging, we help businesses choose between corrugated, chipboard, and other packaging materials based on product needs, cost goals, and supply chain requirements. Whether you need protective shipping boxes or retail-ready cartons, our team can guide you through every step. Contact Brown Packaging today to get started. References Fibre Box Association. (2023). Corrugated Material Basics. Retrieved from https://www.fibrebox.org Paperboard Packaging Council. (2023). Chipboard and Folding Carton Applications. Retrieved from https://paperbox.org Soroka, W. (2016). Fundamentals of Packaging Technology (5th ed.). Institute of Packaging Professionals. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Folding Carton Display Packaging Rigid Box 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
In the world of packaging, the visual appeal of your product plays a significant role in catching the customer’s eye and leaving a lasting impression. Roll End Tuck Top (RETT) boxes, known for their durability and versatility, provide an excellent canvas to enhance the presentation of your products. In this detailed blog, we will explore 12 effective strategies and tips on how to maximize the presentation of your RETT boxes to create a memorable unboxing experience for your customers. Creative Branding Custom Printing Consistency Across Products Window Inserts Custom Die-Cut Shapes Matte or Glossy Finish Branding Inside the Box Personalized Touch Seasonal or Limited-Edition Packaging Professional Photography Creative Branding Utilize the ample space on RETT boxes for creative branding. Include your company logo, eye-catching graphics, and product information. A well-designed box instantly communicates your brand identity and sets the tone for the unboxing experience. Custom Printing Invest in high-quality custom printing to ensure that your RETT boxes are visually striking. Vibrant colors and sharp imagery can make your packaging stand out and pique the customer’s interest. Consistency Across Products Maintain consistency in your packaging design across different products or product lines. A cohesive look reinforces your brand and makes your products easily recognizable. Window Inserts Consider adding window inserts to your RETT boxes. These transparent openings allow customers to preview the product inside, adding intrigue and enticing them to open the box. Custom Die-Cut Shapes Opt for custom die-cut shapes for your RETT boxes to make them unique and attention-grabbing. Unconventional shapes can make your packaging more memorable. Matte or Glossy Finish Choose between matte and glossy finishes to complement your brand’s aesthetics. Matte finishes exude sophistication, while glossy finishes provide a polished and vibrant look. Branding Inside the Box Don’t neglect the interior of your RETT boxes. Adding branding elements, messages, or design accents inside the box enhances the overall unboxing experience and surprises customers. Personalized Touch Consider adding a personalized touch, such as a handwritten thank-you note or a small promotional item, to show appreciation to your customers and leave a positive impression. Seasonal or Limited-Edition Packaging For special occasions or limited-edition products, create seasonal or unique packaging designs. These limited runs can generate excitement and encourage purchases. Professional Photography When showcasing your products online or in marketing materials, use professional photography to highlight the packaging’s visual appeal and its role in enhancing the product presentation. Conclusion Maximizing the presentation of your RETT boxes involves careful consideration of design, materials, and branding. These packaging strategies can significantly impact the customer’s perception of your products and brand. By investing in creative design, custom printing, and unique features, you can create a memorable unboxing experience that leaves a lasting impression on your customers, ultimately contributing to increased brand loyalty and customer satisfaction. If you are interested in roll end tuck top 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. Roll End Tuck Top (RETT) Facebook Twitter LinkedIn Pinterest Relevant Posts
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