First, let’s start high level.

While you might think of your packaging as just a cardboard

box, cardboard and corrugated board are not the same thing. Cardboard is heavy-duty
paper stock, and it’s actually not used for strong shipping containers. A good example of a
cardboard box is a cereal box.
Corrugated board, on the other hand, is a much stronger board that has two main
components: the liner and the medium. The liner is the flat material typically found on the
outside surfaces of the board (but can also be found on the inside of some heavier board
combinations), and the medium, which can be found between the liners. The medium
creates the arched shape or “flutes” between the liners and is a large contributor in the
strength of the board. Once these sheets of paper are glued together they create a
corrugated board which is then converted into a structure that can sustain long shipping
journeys, bumps, and falls. (A lot of things your cereal box would not survive.) When you
go to order your packaging it’s important to know the difference, because chances are
you don’t want to ship your products in a cardboard box.

Learn the Basics of Corrugated Boxes

Before You Get Started With New
Packaging
Now that you know you probably need a corrugated box, you’ll need to figure out what
type of box you’ll need. There’s a number of different factors that go into making your
corrugated box, and it’s one of the reasons why they’re so customizable. Whether you
need a lighter box to help cut down on shipping costs, or a carton made out of a thicker
board grade to provide additional protection, there’s a style of box that’s right for every
product.
First you’ll want to look at flute profiles. The most common flutes used today are A, B, C,
E, and F with A being the largest. Your flute size determines the thickness of the walls of
your corrugated box as well as the stacking strength. “A” flute was the original corrugated
flute and is the thickest flute profile you can use. An A flute is roughly 5mm thick, and is
an excellent option for products that need a little more cushioning or need to have extra
strength for stacking.
B flute was the next profile to be developed and was originally created for self-
supporting products, such as canned goods, that did not require the box to support much
of the load. B flute is roughly 3.2mm thick and is a very popular choice for die-cut
designs.
C flute approximately 4mm thick and the most commonly used all-purpose flute available
today. Although C flute was created after B flute, it is a slightly thicker board with 38
flutes per foot compared to the 47 per foot in B flute.
The most recent flute profiles to be developed are E and F at 1.6mm and 0.8mm
respectively. These profiles are often times used for retail packaging due to their
printability that provides superior image clarity.
 The next aspect you’ll want to look at is the type of board. There’s four types of boards
that can be used for corrugated boxes. The most common types used are single and
double wall. Here’s a description of each:
 Single-Face: One sheet of liner is adhered to one sheet of corrugated
medium. This style of board is typically sold in rolls and can be used to wrap around
products for protection or cushioning.
 Single-Wall: One sheet of corrugated medium is glued between two sheets of
liner. Single-wall board is the most common type of board in the market and can be
used for everything from shipping boxes to retail displays.
 Double-Wall: Two sheets of corrugated medium are glued between three
sheets of liner. This board is commonly used for heavier products, or products that
require a stronger box for shipping.
 Triple-Wall: Three sheets of corrugated medium are glued between four
sheets of liner. This board is the strongest out of all the board styles and is often
used for industrial parts or produce bins.
Once you know what fluting and board type you want for your box, you need to
determine the proper board grade. In order to do so you’ll want to ask yourself – Is it
more important that my box be able to withstand top-to-bottom stacking pressure
without collapsing? Or have increased puncture resistance from internal and/or external
factors?
Corrugated board is categorized as either Mullen or ECT. Although there are situations
where either could be used successfully, the two have different applications. First there’s
the Edge Crush Test (ECT). ECT measures how much stacking strength or pressure a box
can withstand before being crushed. As mentioned previously, the flute profile plays a
large role in the stacking strength of your board. ECT values range from 23ECT single-
wall to 120ECT triple-wall. The higher the number the greater the compression strength.
ECT board is favorable when boxes will be stacked on top of one another whether on a
pallet or warehouse shelf.
The other option for corrugated board is Mullen. Mullen value is determined by the
amount of pressure a box can withstand before bursting or being punctured. The weight
of the board’s liner constitutes the bulk of the bursting strength. Mullen values are given
as a three digit number, such as 200#, and the higher the value the stronger the board.
Finally, you’ll want to choose what style of box you want. There’s a few different types
and they each have different specialties that your product might need:
Regular Slotted Container (RSC)
This is the most common style of box, and typically what you picture in your head when
you think of a package. For this box, all flaps are the same length, and the two outer
length flaps are one-half the container’s width, so that they meet at the center of the box
when closed.

Full Overlap Container (FOL)

This style of box is the same as an RSC except both sets of outer flaps fully overlap one
another to cover the full width of the container. Wider flaps and extra thickness on the
top and bottom of this box make it a better option for products in need of more
protection.

One Piece Folder (OPF)

This is a box just like it sounds, one piece of board that is creased and slotted so it can be
folded into a box with a flat, unbroken bottom. This box is a good option for books and
printed materials.

Full Telescope Design (FTD)

FTD cartons consist of a separate top and bottom that fit over each other with flaps
joining on the side or end panels. When pulled apart, they create two scored and slotted
trays, both with flat bottoms. The full-depth cover slides completely over the body of the
carton providing additional strength around the sides making this style suitable for high
stacking strength of fragile articles.
Once you learn the basics of corrugated boxes, there’s a lot you can do to provide the
best packaging for your products. It’s important to recognize that there are so many
options available, because it’s easy to have a package that’s actually the wrong style for
your product. Talking with a packaging designer can make it easier to determine what’s
best for your needs and the challenges you’re facing.