Types of Corrugated Boxes | What You Need to Know

If you’re new to the packaging game, you probably don’t know a lot about boxes. Luckily, you have come to the right place because we at BoxGenie know virtually everything about boxes after almost 50 years in the industry! 

As a business owner, you shouldn’t think of a box as just a box—it’s so much more than that. It’s a way for your customers to get their hands on your amazing products and help you make a positive impression right off the bat. If you’re looking for a strong box to make a strong impression, look no further than corrugated boxes. 

What Are Corrugated Boxes?

Corrugated boxes are different from your typical flat, light, and bendy cardboard box. Instead of consisting of just a single piece of cardboard, corrugated boxes consist of a liner and a medium. The liner is the flat piece that connects to the medium, which is made up of heavy-duty fluted paper that is able to reinforce the liner thanks to its wavy shape. 

Most corrugated boxes consist of three separate layers—two liners and one fluted medium in between them. This translates into an extremely sturdy container that is able to safely house all sorts of things ranging from food items to mattresses to books and everything in between. 

Why Use Corrugated Boxes?

While it may seem appealing to simply use a basic cardboard box for your packaging needs, corrugated board may actually be a better option depending on your product, your storage method, and your shipping method. But don’t just take our word for it! Here are some of the benefits of using corrugated boxes instead of using plain old cardboard:

• Corrugated boxes are ideal for shipping purposes as they are stronger and more durable than regular cardboard, thanks to their three-layer composition. 
• Corrugated boxes offer insulation that is able to better protect products from temperature changes that are often experienced throughout the shipping process. 
• Despite being super strong and durable, corrugated boxes are still extremely lightweight and won’t cost you much more in terms of shipping costs. 
• Corrugated boxes come in a wide variety of shapes, sizes, and designs so that you’re easily able to find the best option for your products and company altogether. 
• Corrugated boxes can still offer you high-quality printing capabilities so that you can show off your brand and entice your customers before they even open the box! 
• Corrugated boxes can still be recycled so that you can feel good about the packaging products you’re using. 

Different Flute Sizes

One of the factors that you need to consider when choosing a corrugated box is the flute size. As you now know, corrugated boxes are designed with a medium in between the liners that has an arched shape to create “flutes.” 

Flute shape and size contribute to the box’s strength and overall design, and there are several different types to choose from. There are five main flute shapes, and the most common ones are B, C, and E. Here’s a quick description of these different shapes so that you can choose the best one for your shipping needs:

• B flute: This flute was invented after the A flute and is about 3.2 millimeters thick. It is virtually crush-proof and is frequently used for inner packaging components to separate or pad different components within a single shipment. 
• C flute: This flute is the most common type and actually makes up 80% of boards and boxes. So what makes it that popular? For starters, it’s 4 millimeters thick—making it ideal for shipping all sorts of things due to its compression properties and crush resistance. 
• E flute: This thinner flute size is only about 1.6 millimeters thick. It’s a great option to use if you’re looking to reduce storage space or print high-quality images within the retail sphere. It’s ideal for retail thanks to its high printability and ability to feature amazing image quality that will immediately impress customers before they even see the product itself!

Different Types Of Boards

In addition to different packaging types of flutes for corrugated boxes, there are also different types of boards. There are four main types to choose from: single-face, single-wall, double-wall, and triple-wall. Here’s a quick description of these different types of boards so that you can choose the best one for your shipping needs: 

• Single-face: This type of board only consists of a fluting and a liner on one side, rather than on both sides. Even though it’s not extremely durable, it can still function as cushioning or protection within a box. 
• Single-wall: This type of board consists of a fluting sandwiched between two sheets of liner. This is the most common type of board used as it is durable and effective. 
• Double-wall: This type of board consists of two layers of fluting in between three liners—making it extremely durable and ideal for shipping heavier products. 
• Triple-wall: This type of board consists of three layers of fluting in between four liners. This is the strongest type of board out there, which makes it popular in industrial arenas that ship items that require special handling. 

Different Board Grades

Now that you know about board types, it’s time to talk about board grades. There are two main types of board grades: ECT or Mullen, depending on whether the material is more crush-proof or more puncture-proof. 

When choosing your board grades, you not only have to think about the product within the packaging but also the storage environment of the product and packaging. For example, you may want to prioritize ECT (edge crush test) values if your boxes are going to be stacked on top of each other. On the other hand, you may want to prioritize Mullen values if you are packaging sharp or jagged products that have a risk of puncturing the package. 

Different Box Styles

Even though you may think that a box is a box and that’s all there is to it—there are actually several different box styles to choose from when designing your packaging. Here’s a quick description of these different styles of boxes so that you can choose the best one for your shipping needs:

• Mailer Boxes: This is the type of box that comes to mind when you think about your basic box. This type of box is made from a single piece of corrugated cardboard that is then scored and slotted so that you can easily fold it into shape. Mailer boxes are easily shipped and stored since they can remain flat throughout the entire process—they can even be disassembled and re-stored after use!
• Shipping Boxes: These are, as the name implies, large boxes that are ideal for shipping large items or stock. Four flaps at the top fold in to cover and protect the items inside. 
• One Piece Folder Boxes: This type of box consists of a single piece of corrugated cardboard that is scored and slotted so that it is able to fold around the product being packaged. The bottom piece remains unbroken and offers insulation and coverage for products that may be delicate or fragile. 
• Triangle Document Mailer: This type of box is shaped like a triangular prism, and is ideal for mailing important documents, posters, and papers that you don’t want to be damaged. With slotted edges similar to the Mailer Boxes, you can ensure that anything that you’re shipping will arrive safely. 

How To Choose The Best Corrugated Box

When it comes to choosing the best corrugated box, you definitely have a lot to think about! The good news is that you don’t have to make these decisions on your own. In fact, there are experts out there, like BoxGenie, that are dedicated to learning about your brand, your products, and your goals in order to supply you with the best packaging products. 

Not only that but after being involved in packaging for almost 50 years, BoxGenie is able to anticipate your packaging needs and help solve any challenges that you may face along the way. BoxGenie is here to partner with you, listen to you, and share with you real solutions to all your packaging and shipping woes.

Final Thoughts On Corrugated Boxes

As you can see, there are many different components that go into corrugated boxes. For someone new to the packaging game, all of these different components can easily become overwhelming and confusing. After all, you’re an expert in your product and business—how can you be expected to become an expert in packaging as well? 

Thankfully, with the help of BoxGenie, your focus can remain on other business priorities while we assist with the intricacies of finding you the best packaging possible based on your products, storage methods, shipping methods, and overall industry. 

Sources:

1. https://smallbusiness.chron.com/importance-product-packaging-marketing-648.html
2. https://medium.com/thrive-global/19-powerful-ways-to-market-your-brand-ab9e7f2b04e4
3. https://www.forbes.com/sites/viviannunez/2020/04/21/5-things-small-business-owners-should-prioritize-according-to-a-brand-strategist/?sh=3a8ea65456e9