Custom Corrugated Boxes: The Unsung Hero of the Packaging World
Custom corrugated boxes are a cost-effective, strong, and easy way to protect your products during shipment. But, have you ever wondered what makes these seemingly simple boxes so remarkably strong? The answer lies in the intricate science behind corrugated packaging. Here, we’ll go over the construction of corrugated boxes, and help you understand how to create the ultimate packaging solution for your brand.
Understanding the Basics
At its core, a corrugated box is made from three layers of paper — an outer layer, an inner layer, and a corrugated medium sandwiched between them. The outer layers are smooth and provide a printable surface, while the corrugated medium is the wavy, rippled layer that gives the box its strength. The combination of these layers creates a lightweight yet robust structure.
The corrugated material serves as a series of arches within the two layers of smooth material. This design imparts remarkable strength to the box by evenly distributing the weight across its surface. Therefore, the box is resistant to bending and crushing forces.
Factors That Influence Box Strength
Custom corrugated boxes have an exceptional strength-to-weight ratio. This ratio signifies the box’s ability to support a substantial amount of weight relative to its own mass. The liner paper thickness and weight, along with the chosen flute size directly influence the strength-to-weight ratio.
Thickness and Weight of Liner Papers
The right thickness and weight of liner papers significantly impact the strength of corrugated boxes. Thicker liner papers contribute to increased stiffness and rigidity, enhancing the box’s ability to resist bending and deformation. Similarly, heavier liner papers play a role in improving overall stiffness and robustness. A qualified corrugated box manufacturer will help you determine what thickness and weight is optimal for your product.
Flute Size
The secret to a corrugated box’s strength lies in its flute size, which is created during the corrugation process. During corrugation, a sheet of paper is fed through a series of rollers. One roller has a series of grooves, while the other is smooth. As the paper passes through these rollers, it undergoes a unique transformation — the smooth sheet becomes a corrugated one with a distinctive wavy pattern. These waves can be put closer together or further apart, creating something called a “flute size.”
Choosing the right flute size is crucial to ensuring box strength. Flutes come in A, B, C, E, and F options, and they’re all suited to specific industries or applications. Let’s dive deeper into each of these flute options.
A-Flute
At 32-38 flutes per foot, A-flute is the thickest available option. With exceptional cushioning and vertical compression strength, it’s the perfect solution for fragile products. However, the wide space between flutes makes the surface of the board less smooth and not optimal for printing detailed designs.
B-Flute
This flute has 44-52 flutes per foot. It has a stiffer, flat surface that makes it ideal for die-cutting and printing high-quality designs. Originally it was developed to package canned goods and is now commonly used for beverage trays, glass-to-glass packs, and more.
C-Flute
C-flute is the second-thickest corrugated flute available, with 36-41 flutes per foot. Its optimal crush resistance, stacking strength, and printing properties make it the most commonly used flute size for shipping boxes.
E-Flute
E-flute maintains 74-98 flutes per foot, making it much thinner than the profiles mentioned above. Even though it has a slim profile, it has great crush resistance, is easy to fold, and is ideal for printing. It’s a stronger and more environmentally friendly alternative to folding cartons within the retail space. But, it doesn’t make for an ideal shipping container because of its subpar performance in puncture protection.
F-Flute
With 124-128 flutes per foot, F-flute is commonly referred to as a “micro-flute.” it can often be interchanged with E-flute, but it’s most commonly used for specialty packaging, small retail packaging, and clamshell packaging in the U.S. fast-food industry.
Need a Strong Box for Your Packaging Needs? Turn to Tyoga Container
If you need high-quality, strong corrugated boxes that don’t break the bank, turn to the experts at Tyoga Container. With over 50 years of industry mastery, we stand uniquely poised to tackle your packaging challenges with precision. When prompt delivery of top-notch packaging products is non-negotiable, place your trust in us.
At Tyoga Container, our offerings span a diverse range, including stock bulk bags, transit protection, and pallets and crates. However, our true superpower is designing and manufacturing cost-effective corrugated packaging solutions tailored to our client’s specific needs. Regardless of your industry, we possess the acumen to craft the ideal packaging solution for your business.
Equipped with state-of-the-art facilities and a team of seasoned professionals, we not only meet but exceed your expectations, swiftly addressing even the most intricate packaging requirements. We also maintain a variety of certifications — including an FSC accreditation — to hold us to the highest standards in manufacturing excellence. Our dedicated workforce delves deep to understand your precise packaging needs, matching you with suitable stock or customized options to optimize your operations. Moreover, our factories are engineered for rapid SKU changes and short lead times, empowering us to make dynamic adjustments on the go. Whether you need a small or large production run, count on us to make it a reality.
