Corrugated cardboard is a kind of cardboard composed of multilayer paper and fluting sheets. Due to its features of lightweight, and excellent compression, it is an ideal material to produce shipping boxes, mailer boxes, and product packaging boxes.
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Type of the Corrugated Cardboard
The corrugated board comes in five types, single face(2 layers), single wall(3 layers), four layers corrugated board, double wall (5 layers ), and triple wall(7 layers).
Single Face Corrugated Board
The single-face corrugated consists of one piece of fluting and a piece of liner paper, it is also called a two-layer corrugated board. The two-layer corrugated boards are commonly used in customized color mailing boxes.
- Liner paper type: brown kraft paper, white kraft paper, and dyed paper.
- Liner paper weight: 110 gsm,120gsm,130gsm, 140gsm, and 150gsm
- Fluting sheet weight: 115gsm,130gsm, 140gsm and 150gsm
- Fluting type: E flute and F flute
Single Wall Corrugated Board
The single-wall corrugated has three layers, including two pieces of the liner, and a piece of fluting in the center.Some small-size shipping boxes and mailboxes are made of three-layer corrugated cardboard.
- Liner paper type: brown kraft paper, white kraft paper, and dyed paper.
- Liner paper weight: 110 gsm,120gsm,130gsm, 140gsm, 150gsm ,180gsm, 200gsm and 250gsm
- Fluting sheet weight: 115gsm,130gsm, 140gsm and 150gsm
- Fluting type: B flute, E flute, and F flute
Four-Layers Corrugated Board
The four layers of the corrugated board include two pieces of liner and two pieces of fluting.
It is used to custom a high-quality color shipping box.
- Liner paper type: brown kraft paper
- Liner paper weight: 110 gsm,120gsm,130gsm, 140gsm, and 150gsm.
- Fluting sheet weight: 115gsm,130gsm, 140gsm and 150gsm
- Fluting type: AB flute, BC Flute, and BE flute
Double Wall Corrugated Board
The double wall corrugated consists of two pieces of fluting board and three-piece of the liner. It has an additional layer on the top. The double wall corrugated are common materials to make the various shipping boxes.
- Liner paper type: brown kraft paper
- Liner paper weight: 110 gsm,120gsm,130gsm, 140gsm, and 150gsm.
- Fluting sheet weight: 115gsm,130gsm, 140gsm and 150gsm
- Fluting type: AB flute, BC Flute, and BE flute
Triple Wall Corrugated Board
This corrugated board has seven layers, including four layers of liner and three layers of fluting sheet. Compared with other types, it is the thickest corrugated board.
7-layer corrugated cardboard is used for packing boxes of heavy goods (such as motorcycles, pianos, etc.), or for packing large electrical appliances, and machine tools.
- Liner paper type: brown kraft paper
- Liner paper weight: 110 gsm,120gsm,130gsm, 140gsm, and 150gsm.
- Fluting sheet weight: 115gsm,130gsm, 140gsm and 150gsm
- Fluting type: AB flute, BC Flute.
Popular Colored Corrugated Cardboard
In addition to the common brown corrugated board, colored corrugated cardboard is also available. This colored corrugated cardboard is suitable for DIY handicrafts, flower packaging, and the packaging of inner boxes of products
Black Corrugated Board
Black corrugated board is made of black dyed paper, it is available in a 2-layer corrugated board or 3-layer corrugated board.Black corrugated cardboard is mostly used for the inner box packaging of products.
- Liner paper type: black dyed paper
- Liner paper weight: 110 gsm,120gsm,130gsm,
- Fluting sheet weight: 115gsm,130gsm, 140gsm
- Fluting type: E flute and F flute
Colorful Corrugated Board
The Corrugated cardboard can also be customized in different colors according to the customer&#;s requirements, such as red, green, purple, yellow, orange, etc.
These colored corrugated boards are suitable for handicrafts, gift boxes, and flower packaging.
- Liner paper type: dyed color paper
- Liner paper weight: 110 gsm,120gsm,130gsm,
- Fluting sheet weight: 115gsm,130gsm, 140gsm
- Fluting type: E flute and F flute
White Corrugated Board
White corrugated cardboard is made of white Kraft paper, which has food-grade cardboard, It is suitable for baking boxes and other food packaging boxes
- Liner paper type: white kraft paper
- Liner paper weight: 110 gsm,120gsm,130gsm,
- Fluting sheet weight: 115gsm,130gsm, 140gsm
- Fluting type: E flute and F flute
What is the Difference Between Flute Types?
According to the amount and the height of fluting each 30cm, fluting is divided into different types: A flute, B flute, C flute,E flute, and F flute.
These different types of flutes will affect the strength and hardness of the corrugated board, so it is important to know the differences between these flutes.
Flute TypeThicknessFlute number each 30cmFeaturesApplicationA flute4.5-5mm34-36 pcsStrong compression strenghShipping box for light productsC flute3.5-4.0mm38-40 pcsGood compression strength and stackingShipping box for light productsB flute2.5-3mm 47-52 pcsGood hardnessSuitable for packing heavier and hard small size productsE flute1.1-2.0mm96-98 pcshardness and crush resistanceWidely used in various mailer boxes, and it is also suitable for inner and small gift boxes and packaging insert liningF flute0.8-1 mm140-150 pcsthe thinnest boardIt is also suitable for inner box packaging insert lining
How to Choose the Corrugated Cardboard?
When we consider which kind of corrugated board should be selected. Stacking strength, compression resistance, and durability are the three key properties of corrugated paperboard.
What factors will affect the three properties of corrugated paperboard?
First of all, we know that corrugated cardboard is a multi-layer composite material, and the grade of paper has a great impact on its stiffness, hardness, and durable of corrugated.
Among the paper grades of corrugated paperboard, virgin kraft paper is the highest and best in quality.
Secondly, paperweight is another factor that decide the strength of the board, The paperw weight means the weight of square meters of paper. We found that the higher the paper weight, the higher the stiffness of the paper.
Third, different fluting types will also affect the compression resistance. The table above can help you quickly know the characteristics of different flutes.
Finally, the production process of corrugated paperboard will influence its durability.The production process includes the gluing process and fluting structure.
At present, there is U-shaped and V-shaped fluting structures, and U-shaped is better than V-shaped in strength.
Written in the End
I hope this article can help those who have questions about the types and structure of corrugated boards. Help you customize corrugated gift boxes better and faster
If you have other questions about corrugated cardboard, please feel free to contact Better Package, our experts are happy to answer any questions.
Cardboard boxes are designed to protect your materials and products. They are lightweight with firm sides that can cushion impacts and cost less than other forms of shipping containers.
Choosing the Right Cardboard Box Material
There are many types of cardboard boxes on the market, allowing for packaging to be customized to your unique specifications.
With different strength, shapes, sizes, and styles, cardboard boxes offer an incredibly durable and lightweight way to fit many applications.
This article will review the most common types of cardboard used for industrial packaging and help guide you toward making the best choice for your business.
What are cardboard boxes made from?
Cardboard boxes, also known as corrugated boxes or corrugated packaging, are made of multiple layers of cellulose fibres from virgin softwood trees like pine, fir, and spruce.
Nearly all boxes in Ontario and Canada are made with 100% recycled cardboard and paper materials, depending on the box type. However, at the heart of each cardboard box are trees.
The Composition of Corrugated Boxes
Corrugated fiberboard is composed of two main layers:
- Linerboard &#; flat, outer surface between one or more layers of medium.
- Flute &#; wavy, fluted paper in between the linerboards.
Each layer uses a special kind of heavy paper called containerboard with varying strengths depending on the thickness and style used for the liner board and medium.
Contact us to discuss your requirements of Carbonized Cardboard. Our experienced sales team can help you identify the options that best suit your needs.
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- Single face = 1 linerboard + 1 corrugated medium with flutes exposed
- Single wall = 2 sheets of linerboard + 1 layer of corrugated medium
- Double wall = 3 sheets of linerboard + 2 layers of corrugated medium
- Triple wall = 4 sheets of linerboard + 3 layers of corrugated medium
The &#;wavy&#; fluted corrugated layers glued to the linerboard give cardboard boxes their strength.
Kraft Paper
Kraft, which is German for strength, paper is made specifically from softwood trees with long fibres such as spruce, pine, or fir trees. These long fibres create tension in Kraft paper, making it tear and burst-resistant.
Depending on the trees used to make Kraft paper, its colour can vary from brown to yellow. Spruce, pine, and silver birch trees give Kraft paper a rustic brown colour.
In some cases, companies may prefer white corrugated boxes, which is achieved by using bleach on Kraft paper. However, most people stick with the original brown colour for its cost savings and convenience.
Ultimately, Kraft corrugated cardboard is:
- Eco-friendly packaging made from partially recycled materials
- Less expensive than premium white cardboard boxes
- Strong and resistant to damage
Importance of Flutes
The flutes are critical to a cardboard box&#;s strength and structural integrity. Combining different layers of liners and fluting creates different levels of protection.
Generally, smaller flutes will be used for retail packaging, as they have the right structural protection and graphic stencilling options.
Larger flutes, especially those with multiple layers, provide superior strength, compression resistance, and cushioning. However, this impacts the weight &#; affecting the overall cost of the cardboard.
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Flutes are standardized into various sizes, with A or B fluting being the ideal choice for heavy-duty and industrial packaging
Standardized flutes include:
- A flute: 1/4" or 5mm in thickness; approx. 33 flutes per foot
- B flute: 1/8" or 3mm; approx. 47 flutes per foot (common for canned goods)
- C flute:
11/64" or
4mm; approx. 39 flutes per foot (
popular for shipping cartons)
- E flute:
1/16" or 1.5mm; approx. 90 flutes per foot
- F flute:
1/32" or
2mm; approx. 125 flutes per foot (
used for retail packaging)
As you read above, cardboard boxes can be composed of various layers of flutes. Those with double or triple walls can have varying fluting layers. The most popular option for double-wall cardboard is a BC flute, using both a B flute and a C flute to enhance the protective properties of a box. The most popular for tri-wall is ACC flute.
The style of flutes used for corrugated packaging is designed to support a great deal of weight. Not only is this beneficial for shipping purposes, but also cushioning and insulation, contributing to protecting goods inside corrugated cardboard boxes. Larger flutes provide more protection, as they can absorb more shock, while shorter flutes have a greater crush resistance.
Edge Crush Test and Mullen Strength
Strength of cardboard is also impacted by the thickness of paper used, measured by Edge Crush Test (ECT) or Mullen testing.
ECT measures verticle strength by applying pressure downward along the verticle edge. The higher the strength the higher the stacking capacity. Single wall C-Flute is commonly available in a 23ECT, 29ECT, 32ECT 40ECT, 44ECT. Double wall BC flute is commonly availble in 42ECT, 48ECT, 51ECT. Tri-wall ACC flute is commonly available in 67ECT & 80ECT. Alternative board grades are also available.
Mullen measures the burst resistance, it is measured in PSI, increasing pressure (weight) is applied to a small section of the board until it bursts. For example a 200lb test carton has a 200lb puncture resistance. 200lb is a common single wall, 275lb is a common double wall, 900lb is a coomon tri-wall.
Is corrugated cardboard cost-effective?
Corrugated cardboard is one of the most customized and least expensive packaging materials. It uses advanced computer design and manufacturing systems to produce corrugated boxes that meet any specifications.
Having the right cardboard box material and style helps to:
- Protect your products and materials &#; Corrugated boxes are stronger than regular cardboard boxes. They vary in size and thickness, offering a durable cushion and support during shipping and handling.
- Easy to customize
&#; With corrugated cardboard, there is no one-size-fits-all. Instead, we can help customize, design, and create cardboard boxes that meet your needs and shipping requirements.
- Withstand moisture
&#; Corrugated cardboard is designed to keep moisture and bacteria away from the products within, ensuring the sterility and safety of products.
- Cost-effective and sustainable
&#; Corrugated cardboard is not only inexpensive, but it&#;s also easily recyclable. If you need a sustainable solution for your packaging needs, go with this.
- Lightweight &#; if you&#;re transporting heavy manufacturing products, you don&#;t want any more weight to increase the shipping costs, right? This is why corrugated cardboard is advantageous, as it is both strong and lightweight.
What cardboard box style should you order?
When it comes to protecting your products and materials &#; the size, strength, and durability of corrugated cardboard are crucial.
Here are a few cardboard box styles to choose from:
- Regular Slotted Carton (RSC) &#; Pre-cut and pre-creased corrugated sheets commonly used to protect most products. RSC cardboard boxes have four flaps with the same width with two of the four flaps having longer lengths that meet at the center of the box when completely folded.
- Full Over Lap (FOL) &#; Heavy-duty cardboard box with flaps that extend all the way to the opposite side of the box when folded, adding stacking and structural strength to the box. Ideal for storing and shipping products.
- Cut Out Wrap (COW) &#; Made of one sheet of corrugated cardboard with all four corners &#;cut out&#; that fold and meet in the center. COW boxes are inexpensive as well as fast and easy to assemble.
- 5 Panel Wrap &#; Consists of a single cut and scored corrugated piece of cardboard with a fifth panel that serves as a closing flap to cover the side panel completely. Ideal for shipping long, heavy or flat products.
Each of these types of corrugated cardboard boxes are available in the following grades:
- Single wall corrugated boxes
&#; the most common type of corrugated cardboard boxes, using 2 outer liners and a fluting layer. Perfect choice for economical packaging and rigidity for lightweight items.
- Double wall corrugated boxes
&#; more durable than single wall cardboard, made using 3 layers of liners and 2 layers of fluting. Ideal for shipping, storing, and distributing heavier industrial items.
- Tri-wall corrugated boxes
&#; superior protection and durability with 4 liners and 3 layers of fluting. Best for shipping chemicals or as an alternative to wooden crates for optimal cost-savings.
For protection in extreme environments and conditions, custom wood crating would be the safest way to transport your products. At SmartShield, we design and develop crates to fit any product&#;s specifications. All wood crating is designed using our cutting-edge SolidWorks program, which provides the exact dimensions needed to fit and protect your products.
Get customized cardboard boxes
Custom packaging can be fitted to almost any product shape if you&#;re looking for the right way to protect your items. Our precision-controlled CNC technology and professional design team work with you to ensure every valuable item &#; big or small &#; stays protected during transportation or storage.
Get in touch with a custom design expert and eliminate your packaging challenges.
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