What are the important factors to consider when deciding on packaging? Protection and promotion right? If your brand packaging lacks these two basic qualities you may experience a downfall as over 90% of consumers are concerned about quality packaging when buying a product. But this blog is curated to solve this problem. There’s a packaging solution that offers all-in-one packaging and the hero of the hour is custom corrugated boxes. These boxes are an imperative part of everyday life from shipping products to moving houses. The sturdiness is their most prominent feature however in this blog you will get to know all other benefits, applications, manufacturing, and a short history of corrugated boxes. Just continue reading and shift your packaging to corrugated boxes if you haven’t done it yet!
History Of Corrugated Boxes
The corrugated boxes are as old as plastic. It dates back to 1856 when Edward Allen and Edward Healey wanted to discover a way to keep the shape of their tall hats and ended up inventing a corrugated paper used as a stiffening liner for their hats. However, the official packaging use of custom corrugated packaging was started in 1871 when Albert Jones patented a single-sided corrugated cardboard. Now various specifications are being added and corrugated containers can be seen at any nearby stores or even in our households.
Distinct Types Of Corrugated Boxes
Corrugated boxes are made from kraft paper that can be customized into any shape or type to meet various requirements. The ultimate feature of corrugated packaging boxes is their flexibility as you can personalize the number of walls, flutes, materials, and liners. Here some types are elaborated to help you understand better:
Single-Faced Boxes
Single faced corrugated boxes have two layers one is liner and the other is fluted. This type of box is typically used for small or irregular shapes products and also has maximum flexibility. This type is commonly used for food packaging boxes.
Single-Wall Boxes
This type of corrugated box contains one fluted layer between two liner boards. They are not only economical but lightweight. Custom Mailer boxes are normally made with single-wall corrugation.
Double-Wall Boxes
Double wall corrugation has two fluted layers that are layered between three-liner boards. This type provides maximum strength with fertility and gives efficient shipping just like cardboard boxes.
Triple-Wall Boxes
This type of corrugated box is best for extremely heavy items and oversized products. Three layers of flutes are placed between five liner boards which makes it an ideal choice for long-distance shipping.
Folding Boxes
Folding corrugated boxes canada offers foldable designs for easy storage and shipping. This is the best option for point-of-sale packaging, retail displays, and e-commerce just like kraft boxes.
Flute Types Of Corrugated Boxes
The flute is a zigzag paper that is layered between two linerboards. Flutes and liner boards combined make a corrugated material. The flutes prevent punchers and crushing while shipping while giving a solid structure to your boxes. Here is how different flutes contribute to the flexibility:
- A flute (36-40 flutes per inch, 4.5-5.5 mm thickness)
- B flute (47-53 flutes per inch, 3.5-4.5 mm thickness)
- C flute (39-45 flutes per inch, 4-5 mm thickness)
- E flute (90-110 flutes per inch, 1.5-2.5 mm thickness)
- F flute (125-140 flutes per inch, 1-2 mm thickness)
- G flute (120-140 flutes per inch, 1.5-2.5 mm thickness)
- H flute (150-170 flutes per inch, 1-2 mm thickness)
Advantages Of Corrugated Boxes
After reading all the types and flutes choices you must get an idea that these boxes are perfect for brands looking for protection at maximum. But don’t stress as corrugated containers have much more to offer as they also reduce packaging costs. Delve into some potential reasons before selecting corrugation material as your next packaging solution:
Sustainability
As per 2024 statistics in Canada, consumers are more likely to buy products with sustainable logos. Also, staying with environmental as well as packaging trends is necessary to beat up the competitive market. Corrugated material is 100% recyclable thus giving you a bonus to maintain a reputation even in the eyes of eco-conscious people.
Cost-effective
For businesses that have a small amount of investment to spend on packaging, corrugated boxes wholesale is a vital option to consider. These boxes do not require expensive manufacturing and due to being lightweight the shipping costs are also comparatively low as compared to other materials.
Lightweight
As mentioned above, corrugated boxes are lightweight because they are made with thin materials like paperboard and kraft paper. No matter what the box dimensions, these boxes are never difficult to ship. However, the strength and durability remain the same always regardless of how many flutes are preserved between linerboards.
Customizable
These boxes are customizable and can be tailored to any product-specific needs. You can even include shelves or pockets to display your items effortlessly in custom boxes. The permeable surface of these boxes makes it easy to add special stickers and labels.
Durable
Here comes the most prominent trait which is durability. The structure of these boxes are sound which makes them resistant to impact, tear, and moisture. The durability of printed corrugated boxes makes them proper for long-term storage as they remain in good condition even if kept for years.
The Manufacturing Process Of Corrugated Boxes
The production of corrugated packaging requires several steps. These boxes can become your ideal packaging partner only if you choose the manufacturing process wisely. Look for companies that provide quality boxes without pinching your pockets just like PremiumCustomBoxes. Moreover, if you want custom packaging for small businesses, then they are the ultimate choice for you.
Raw Materials
First, choose one of the suitable raw materials for the outer layers such as Kraft or paperboard.
Corrugating
Unwind the Kraft roll, feed the paper into the corrugated machine, and then create the desired fluted layers i.e. A, B, C, E, F, G, H (details mentioned above).
Lining
After that apply adhesive to attach the fluted layers to the kraft liner to complete the lining process.
Creasing
Creasing corrugation involves making fold lines for easy folding and assembly of the box. This step helps reduce waste and rejects for your retail boxes canada.
Cutting
Cutting involves trimming the paper sheets into desired shapes and sizes. A lot of cutting options are available in the market including:’
- Die-cutting
- Laser cutting
- Shear cutting
- Rotary cutting
- Water jet cutting
The most common cutting method is die-cutting, which is known to make precise cuts for apparel boxes or any other container.
1. Printing (Optional)
If you do not subscribe to the printing option then your boxes will result in a natural brown color. As the corrugated material is print-friendly, you can get any pattern, graphics, brand logo, name, or any other product information on them. White corrugated boxes will be appropriate to consider for gift boxes design with different personalized quotes or messages on them. Here are some common printing techniques:
- Offset printing
- Digital printing
- Flexographic printing
- Screen printing
- UV printing
2. Folding And Gluing
In this process, the flat corrugated sheet is transferred into a well-shaped box. You can choose from the straight fold, crease fold, and tuck fold. After folding the box, special gluing techniques are applied to the folded components to make them intact.
3. Quality Control
This step may be underrated but is most important for efficient manufacturing. Quality control involves inspecting the boxes from corner to corner and analyzing if the dimensions, shapes, printing, and coatings are driven as requested.
Closing Remarks
Corrugated boxes have revolutionized the packaging industry with their versatile applications and advantages. From retail stores to online businesses, these boxes continue to give maximum quality and flexibility. At PremiumCustomBoxes, you can choose your desired shapes, sizes, materials, printings, coatings, and even delivery times. Just search for corrugated boxes near me and our website will be popped up at the top as we are the best packaging company in the whole of Canada.
