How Corrugated Packaging is Made & When to Print with Corrugated Material


Corrugated packaging is a durable, cost-effective, and versatile packaging material that’s made from 3 or more sheets of corrugated fiber board (also known as container board). Corrugated boxes are made from a flat material called liner board and a medium, which is paper that’s formed into flutes and glued between liner board.

  • Stronger than Cardboard: Safe, sturdy and protective, corrugated boxes are stronger than cardboard, so you can feel confident that whatever you put inside will stay safe and sound. Corrugated packaging is also crush and pressure-resistant.
  • A Wide Range of Sizes: Corrugated packaging is available in a wide range of sizes. Although it’s strong, it’s also lightweight, making it a great fit for nearly any type of product that needs to be protected, but without the added weight.
  • Can Be Broken Down and Reused: Corrugated boxes can be broken down and stored easily or transported without affecting the structural integrity of the packaging.
  • Good for the Environment: The packaging material itself is made from recycled and renewable materials, such as Kraft, making them an Eco-friendly packaging option that consumers will appreciate.

Corrugated boxes are made of three different layers of paper: an inside liner, an outside liner and fluting which runs in between. The flutes between the layers of liners give strength and structure to corrugated boxes and provide an extra layer of protection. This corrugated method, also known as container board, ultimately helps provide the strength needed to hold weight and protect the product inside.

The strength of a corrugated box starts with its material. A box’s strength is relative to its density. The more walls a box has, the stronger it will be. The manufacturer’s stamp inside the box usually states single wall, double wall, or triple wall to let you know the strength of the box.

Because all Custom Corrugated Packaging Boxes are not made the same, the outer and inner dimensions may vary, meaning that the weight the box is able to carry can also vary. Calculating the box size also allows businesses to make informed decisions about logistics and supply chain management, but box size will not affect the strength of the box overall.

Corrugated cardboard works for produce trays because it is strong and lightweight, and can be made into stack able trays. Corrugated cardboard produce trays can be plain or be custom printed with your branding for easy identification in transit and on the retail shelf. In terms of efficiency, corrugated cardboard provides space-efficient packaging which is ideal for transportation, and at the end of its life, corrugated packaging breaks down and is easy to dispose of.


There used to be a time when consumers would make a purchase and it wouldn’t matter where that product came from, where it had been made, or what it had even been made out of.

However, ethical shopping has become much more integral to the purchasing process and customers across the other Countries are choosing suppliers that are making reasonable efforts to be environmentally friendly.

A recent Unilever study revealed that a third of consumers prefer sustainable brands. So businesses will find more now than ever before, shoppers want more information on what their products contain and how they’ve been manufactured.

What is corrugated cardboard used for?

So, just how does corrugated cardboard work?  This innovative construction features three separate materials and gets its super strength from the combination of all 3 working together.  In the center, the concertina card is tightly but firmly packed within two layers of fluting and this gives strength across the width of the card to both sides of the material. It’s this concertina structure that makes the card super strong.

With many different types of cardboard box available, Other Companies often get asked which is the right one to use, and how thick is corrugated cardboard?  The great thing about how it’s made means that many different types and strengths can be produced.


The majority of box styles fall into one of the following general categories: Slotted Boxes, Telescope Boxes, Folders, Rigid (or Bliss) Boxes, Self-Erecting Boxes and Interior Forms. In addition, corrugated boxes can be custom corrugated designed to meet the specific needs of the customer.


These boxes are generally made from a single piece of corrugated fiberboard. The blank is scored and slotted to permit folding. Boxes are shipped and stored flat and assembled as needed by the user. Some of the most common types include:

Regular Slotted Container — All flaps have the same length, and the two out flaps are one-half the container’s width, so that they meet at the center of the box when folded. The Different Companies is the most common box style.


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