The corrugated industry, which primarily manufactures corrugated cardboard boxes, displays, and other packaging materials, is a critical part of the global supply chain. When people have basic questions about this industry, they often center on the product itself, its manufacturing process, and its uses.

Here are some of the most common basic questions asked about the corrugated industry:

What is the difference between “cardboard” and “corrugated”?

This is a very common point of confusion.

• Cardboard is a general term for a thick paper stock or a heavy-duty paper. It’s used for things like cereal boxes, shoe boxes, or greeting cards. It’s a single, solid sheet.
• Corrugated material, also known as corrugated fiberboard, is a much stronger and more durable material. It is made up of a fluted (wavy) inner layer, called the medium, sandwiched between one or two flat outer layers, called linerboards. This multi-layered structure is what gives corrugated boxes their strength and cushioning properties, making them ideal for shipping and storage.

What are corrugated boxes made of?

Corrugated boxes are primarily made from a paper product called containerboard. This material is typically made from a mix of virgin wood fibers and recycled paper fibers. The use of recycled materials makes the industry highly sustainable and environmentally friendly.

How are corrugated boxes manufactured?

The process involves several key steps:

• Pulp Preparation: Recycled paper and/or new wood fibers are processed into a paper pulp.
• Corrugation: A large machine called a “corrugator” heats and forms the flutes in the medium paper.
• Lamination: The fluted medium is then glued to the flat linerboards, creating a corrugated sheet.
• Cutting and Printing: These sheets are cut to specific sizes and shapes, and any necessary graphics, logos, or information are printed on them.
• Folding and Gluing: The flat “blanks” are folded and glued at the joint to form the final box. They are then bundled and shipped flat.

What are the different types of corrugated board?

The strength and thickness of corrugated board vary depending on its construction. The most commonly used types are:

• Single Face: One fluted medium glued to one linerboard.
• Single Wall: One fluted medium sandwiched between two linerboards. This is the most common type for shipping boxes.
• Double Wall: Two fluted mediums and three linerboards. This offers extra strength for heavier items.
• Triple Wall: Three fluted mediums and four linerboards. This is used for very heavy or industrial-grade packaging, sometimes as a substitute for wooden crates.

The size of the flutes (the wavy arches) also varies and is designated by letters (e.g., A, B, C, E, F). Different flute sizes provide different benefits, such as cushioning, stacking strength, or a better surface for printing.

How is the strength of a corrugated box measured?

There are two primary tests for measuring a box’s strength:

• Edge Crush Test (ECT): This is the most common test today. It measures the stacking strength of the box, or how much force it can withstand on its edge before collapsing. It’s ideal for products that are shipped on pallets and stacked.
• Mullen Test (or Burst Test): This test measures the force required to puncture or burst the corrugated board. It’s more relevant for products that are shipped individually and might be subject to rough handling.

Can corrugated boxes be recycled?

Yes, corrugated boxes are one of the most widely recycled paper products. They are made from a high percentage of recycled content and are themselves 100% recyclable. For recycling, it’s important to remove any non-paper packing materials and flatten the boxes.

Why is corrugated packaging so popular?

Corrugated is the packaging material of choice for many industries due to its:

• Durability and Strength: Provides excellent protection for products during shipping and handling.
• Lightweight: Reduces shipping costs compared to heavier materials like wood or plastic.
• Sustainability: Made from recycled content and is easily recyclable.
• Cost-Effectiveness: Generally less expensive than alternative packaging materials.
• Versatility and Customization: Can be manufactured in a vast range of sizes, shapes, and strengths, and can be easily printed for branding and product information.

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