In the modern and ever-expanding world of e-commerce, retail, and global trade, packaging boxes have become an integral part of doing business. Among different options, corrugated boxes have emerged as the backbone of efficient and effective packaging. Known for their strength, versatility, and eco-friendliness, these boxes are essential for displaying, storing, and shipping across a wide range of industries. Such features have made them the top choice of numerous brands. But how exactly are they made, and what techniques do corrugated box manufacturers adopt to provide brands an impeccable form of packaging? In this guide, we answer these questions as we take a deep dive into the corrugated box manufacturing process. From raw materials to final products, from machinery to quality control, and from sustainability practices to future trends, we will discuss everything. Before we get down to real business, let’s briefly explore corrugated boxes and their uses.
A corrugated box is a packaging carton made of a fluted (wavy) inner layer sandwiched between two flat sheets of paper. The thickness of the inner and outer sheets can be customized as per a brand’s needs and the nature of the product. The three-layer structure creates a box that is both strong and lightweight, offering more protection than single-sheet boxes.Corrugated boxes are different from regular cardboard, which has only one layer. Rigid boxes, when compared to corrugated packaging, are sturdier, made from thick paperboard, and often used for luxury packaging. They are best used for presenting luxury goods and a premium look.The common uses of corrugated boxes include shipping and mailing, retail packaging, and storing & warehousing. They are often used as display boxes at point-of-sale points. Their durability gives them the strength to withstand the wear and tear in a rigorous retail environment.
Corrugated boxes get their strength due to the raw materials used in their making. The paper is typically sourced from wood pulp or recycled papers. The main parts of the box are flat & plain linerboard and the corrugated (ridged) medium. The flat part is on the outside of the box, while the ridged part is between the flat sheets. Most box manufacturers use Kraft or cardboard to make the corrugated boxes. Kraft, made from softwood paper, is famous for its strength and eco-friendly properties. Cardboard stock is also another option for making corrugated boxes.It is known for its flexibility and versatility in terms of die cutting and printing. Mailer boxes are usually made from cardboard.
This phase consists of two sub-steps. The process begins with fluting the medium. It is done with the help of a corrugator machine which shapes and bonds the paper layers. When you are selecting your custom box supplier, make sure you ask them about which machines they are using and if they can handle your box requirements. The medium is softened using steam and pressed with the help of corrugated rollers to give it a wavy shape. The wavy part is then glued to the flat sheets. This forms a single-face board, which can then be bonded with another linerboard to create double-wall or triple-wall boards. Once the sheets have bonded, they are dried, cut into large panels, and stacked for further use.
The corrugated box you see passes through a lot of stages before it comes to its final shape. The first step in the process is printing, in which corrugated box manufacturers add logos, instructions, images, and branding elements onto the outer linerboard. The best printing method for this phase is flexographic, as it uses quick-drying inks, making it excellent for high-speed production runs.After printing, the boxes are scored with the help of large machines. The purpose of scoring is to make it easy for warehouse staff to fold and assemble the boxes. Then the boxes are slotted to cut out the flaps. Die-cutting may also be needed to create custom shapes and handles, if required. The next step is folding and gluing. The boxes are shaped and sealed using glue or large metal pins. At last, the boxes are then bundled into stacks, strapped, and made ready for shipping.
Corrugated boxes come in different styles to meet the various needs of buyers. The most common one is the Regular Slotted Container (RSC). All the flaps in these boxes are of the same length and meet at the center when the box is closed. It is ideal for general shipping purposes. The other common type is die-cut boxes. These are custom-designed boxes made to a specific size and shape. Full Overlap (FOL) boxes, used for heavy and fragile items, have flaps that completely overlap each other. Last but not least, telescoping boxes consist of two pieces that slide over each other. They are typically used for large or flat products like maps and artwork.
If you work with the best box suppliers in the US, they will deliver the boxes after passing them various tests. For example, one of the tests is the Edge Crush Test (ECT), used to measure a box’s ability to withstand stacking pressure. Flat Crush Tests are applied to examine the strength of the fluted medium. Water tests are conducted to determine how well the boxes handle the moisture in the air. Apart from these tests, most manufacturers also randomly test the dimensions of the box to ensure consistency. Adopting these quality control measures not only protects the integrity of goods during shipping but also builds customer loyalty and increases sales.
Safeguarding the planet is a moral and legal responsibility of every manufacturing concern. Most manufacturers pay special attention to conserving the environment during the production process. Apart from this fact, corrugated packaging is considered to be one of the most sustainable options in the industry. Over 90% of the boxes in the US and worldwide are made from recycled materials.The paper used in the making of corrugated boxes is biodegradable. It is often sourced from managed forests, ensuring a renewable supply chain. Moreover, various innovations such as water-based inks, eco-friendly adhesives, and lightweight designs minimize material use without affecting the strength of the box.
The biggest challenges in the corrugated box industry are fluctuating prices, raw material availability, and energy usage. The corrugation process needs a significant amount of steam and energy. The other problems include supply chain issues and increased demand for small, customized batches of boxes. It increases the cost of manufacturing for producers.Just like all the other sectors and industries, corrugated boxes have also been positively impacted by technology. Smart packaging measures like using QR codes are not only helping brands but also their buyers. At the manufacturing stage, AI integration is helping streamline the production processes.
Now that you know everything about the manufacturing process, it is time to guide you on how you can get these boxes. For this purpose, Packaging Mania, one of the best corrugated box manufacturers in the US, is right here to help you with all your box needs. Reach out to us now and let us offer you the best custom packaging boxes for your brand.
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