The Master Guide To Corrugated Packaging
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The document provides a comprehensive overview of corrugated packaging, emphasizing its structure, benefits, and types, distinguishing it from cardboard. It highlights the growing demand for corrugated boxes driven by the e-commerce industry and discusses various paper grades used in their production. Additionally, it covers quality control tests for assessing the strength and durability of corrugated materials.
The Master Guide To Corrugated Packaging
- 1. The Master Guide To Corrugated Packaging
- 2. Corrugated - An Overview The everyday corrugated box is the most common as a shipping and mailing option. Most companies use corrugated boxes to efficiently ship and deliver enormous amounts of products over long distances.
- 3. What is Corrugated Fibreboard? The conventional corrugated box has 3 fiberboard layers in its structure. The outer layers are called linerboards, and the wavy layer of paper sandwiched in between the linerboards is called the flute.
- 4. What is Cardboard? Cardboard in the packaging industry refers to thick paperboard material used to make folding carton boxes.
- 5. What’s the difference between corrugated and cardboard? Raw materials used for the packaging Durability How the packaging is used Key differences between the two include:
- 6. The Benefits of Corrugated Packaging Protection: Corrugated is one of the best packaging options available for those seeking to protect their items during transit. It can handle the impacts of being moved around and shipped, and the cushioning offers a lot of support. Durability: Corrugated boxes are durable because of their protective features. The boxes can withstand a lot of impact without damaging the products inside. Environmentally-friendly: Corrugated boxes are made of recycled fibers and are easily recycled making them a better contender for sustainable packaging. Customizable: Corrugated boxes are flexible, making them easy to manipulate into various shapes. The surface of the linerboards also offer exceptional opportunities for branding through printing.
- 7. The Corrugated Industry Corrugated packaging is used across the retail industry and is becoming more needed as e-commerce sales shoot up. In 2021, the e-commerce industry is projected to increase to 2.14 billion shoppers, leading to a higher demand for this kind of packaging in retail.
- 8. Types of Paper Liners Linerboards are available in a variety of paper grades. Paper grade choices are made based on branding specifications for businesses. This could include sustainability efforts, artwork designs and the purpose of the packaging itself. Let’s dive into the various types of paper liners.
- 9. Kraft Liners Kraft paper consists of 70-80% “virgin” pulp fiber, which results in a top tier paper grade that is very stiff and durable. Kraft paper liners are the most sustainable option compared to other paper grades available. However, it is also the most costly.
- 10. Types of Kraft Liners White Top Kraft Very strong, affordable and offers a smooth surface for high quality printing capabilities Mottled White Kraft (Oyster Kraft) Very similar to White Top Kraft but features a textured appearance. Fully Bleached Kraft Put through an additional bleaching process to feature a brilliant white color with a smooth surface for printing. It is the least sustainable kraft liner board option.
- 11. Test Liners Test paper is a less costly option than Kraft and is commonly used as the linerboard for the interior of corrugated boxes. There is a higher percentage of recycled-fiber content, resulting in a less durable paper liner that is difficult to print on.
- 12. Types of Test Liners Test Liner 2 made from partly recycled content Test Liner 3 made from fully recycled content White Top Test Liner is made from recycled content and features a white, clay coated surface Oyster Test Liner is made from recycled content and looks similar to white top liners but features a mottled surface
- 13. Flute Paper The flute of corrugated packaging is also available in a few different paper grade options. Flute paper grades play a crucial role in the durability of corrugated boxes.
- 14. Types of Flute Paper Semi Chem made using virgin fibers and a neutral sulfite semi- chemical process to give it an off-white color. Waste Based Fluting made from 100% recycled fibers and tends to be gray/brown in color.
- 15. Flute Grades Flutes are essentially corrugated shaped liner boards that are placed between 2 flat liner boards to provide cushioning, strength and compression resistance to corrugated boxes. Available in a variety of thickness options, flute grades can be customized to support heavier weight products more effectively.
- 16. Thickness Options Single face: commonly used to wrap products for extra protection. The fluted fibreboard is glued to one flat sheet of linerboard leaving the fluting exposed on one side. Double-wall: Commonly used for shipping boxes and mailers. Two sheets of fluted fibreboard are glued between three sheets of linerboard. Single wall: Commonly used for packaging lightweight products. The fluted fiberboard is glued between two sheets of linerboard. Triple wall: Commonly used for packaging heavy weight products. Three sheets of fluted fibreboard is glued between Four sheets of linerboard and three corrugated fiberboards in between.
- 17. Single Wall Flute Types A-Flute - 1/4" has the highest protection and cushion qualities. Very good at handling compression and stacking. B-Flute - 1/8" has a flatter surface and is very lightweight, yet still offers durability, structure and strength.
- 18. Single Wall Flute Types C-Flute - 3/16" one of the most versatile flute grades in corrugated boxes, It has average crush resistance, stacking strength, and printing capabilities. E-Flute - 1/16" a thinner flute grade, E-Flute is often used as an alternative for paperboard folding cartons. E-Flute - 1/32" has protective qualities similar to E-Flute but with an even smoother surface for high-quality printing.
- 19. Double Wall Flute Types AC Flute a combination of A flute and C flute, two of the most protective flute types. BC Flute a combination of B flute and C flute, this flute type provides high-level transit protection. EB Flute a combination of E flute and B flute, provides excellent strength and protection, while the outer liner allows for a high quality printing surface.
- 20. Quality Control Tests The Edge Crush Test Force is applied perpendicular to the edge of the corrugated board until it buckles. The results provide manufacturers the confidence that the material has the strength and durability required to handle heavy loads and stack resistance. The Burst Test (Mullen) Force is applied to the surface of the corrugated board until punctured. This test challenges the durability of the corrugated fibreboard and provides manufacturers with a better understanding of how the box will perform in transit. There are different ways to test the strength of corrugated material.
- 21. In essence, these two certificates provide the same information. The Box Manufacturer is indicated in the outer ring. Board Construction is the information displayed directly under where it says “box certificate, indicating the construction and thickness of the box. City & State is the final information stated on the box at the bottom of the label. This is where the box is constructed and shipped from. The Box Marker Certificate ECT-Rated BMC Mullen-Rated BMC There are 2 versions of box maker’s certificates:
- 22. With a good understanding of corrugated packaging, businesses have the power to establish brand credibility and an exceptional customer experience. Contact our packaging specialists today to find out more about how you can use corrugated packaging for your product! www.pakfactory.com/contact-us