Corrugated vs. Flexible Packaging
The two basic layers of corrugated packaging are the liner — the flat outer layer — and the medium or fluting — the inner, corrugated layer. An adhesive sticks these layers to one another. Some corrugated packaging is single-walled. Double and triple-walled packaging are also available to provide more sturdiness and stability.
Cardboard vs. Corrugated Shipping Boxes: What’s the Difference?
While ordering packaging and shipping materials to transport products to customers, it’s important to know what you’re ordering — and if it will protect your product during shipping.
The most common options for shipping containers are carboard boxes and corrugated boxes.
Both are used by thousands of brands every day, and the differences between the two types of boxes help businesses decide which one is right for them.
Some business owners may not even realize there is a difference between carboard and corrugated shipping boxes. Oftentimes many people use the words “corrugated” and “cardboard” interchangeably because they don’t know there is a difference.
But choosing the proper shipping box to ship your products can make a substantial difference.
What is a corrugated box?
A corrugated box is a shipping box built with layers of cardboard-like sheets on each side.
The word “corrugated” refers to a specific type of kraft material that is made up of three different sheets of container board.
Corrugated boxes are comprised of a fluted, or ruffled, corrugated sheet and two outer flat linerboards. The material is quite durable and can withstand tough conditions. The layers enhance the packaging process for the following reasons:
Durability
Lightweight with an ideal strength-to-weight ratio
Product protection
Cost-effective
Environmentally friendly
Once the box is formed, it creates the ideal shipping container for almost any product.
Packaging engineers design corrugated shipping boxes to fulfill the needs of the product being shipped and the hazards of the shipping environment — shock, vibration, moisture, or compression.
What is a Cardboard Box?
A cardboard box is simply a box made from single-layer cardboard.
The same material is also used to make cereal boxes and even greeting cards.
Simply put, the term “cardboard” is used to describe almost any type of board that has been made from heavy paper-pulp and, unlike corrugated boxes, is not layered to make a shipping box.
While cardboard boxes can work for some situations, they are typically not strong enough to withstand the shipment of products safely and securely.
If a business were to select regular cardboard as opposed to corrugated shipping boxes, it might not give your business the representation it deserves — especially if something is received damaged.
Why Corrugated Boxes Make a Difference
While the differences may seem slight, it can mean the difference between a package arriving safely or damaged.
When you take into consideration that cardboard and corrugated shipping boxes are made from different materials, it certainly makes a difference for packaging and shipping purposes.
It is clear that cardboard boxes will not provide the protection your products deserve — and customers expect.
Corrugated, on the other hand, offers a durable product that can withstand shipping conditions. But they are light enough to still be recycled and broken down after shipping.
Corrugated boxes can also come in a variety of sizes, allowing you to choose the best size for the product, while cardboard might not.
What is Corrugated Packaging? How Corrugated Packaging is Made & When to Print with Corrugated Material
Corrugated packaging is everywhere.
More than 95% of all goods consumed in North America are packaged and transported in corrugated packaging. Corrugated boxes are universal – both at work and at home. A true staple of the retail world.
But what exactly is corrugated packaging? Why is corrugated material so commonly used? And when should corrugated packaging be used?
What is Corrugated Packaging?
Corrugated packaging is a durable, cost-effective, and versatile packaging material that’s made from 3 or more sheets of corrugated fiberboard (also known as container board). Corrugated boxes are made from a flat material called linerboard and a medium, which is paper that’s formed into flutes and glued between linerboard.
Who Invented Corrugated Packaging?
Corrugated packaging as we know it goes back more than a century, born from the need to package and store goods for a longer period of time.
In 1856, Healey and Allen, two Englishmen, secured a patent for the first known use of corrugated paper. Using two fluted rolls, corrugated paper was fed through a hand-cranked machine, creating fluted paper lining that could be placed in hats.
But corrugated paper for hats is one thing, and corrugated packaging for transporting products is completely different. An American named Albert S. Jones is responsible for this combination, and was the first person known to use corrugated paper to wrap fragile items like bottles and other easily breakable goods in a similar way that corrugated packaging is used today.
How is Corrugated Packaging Made?
The process for creating corrugated packaging hasn’t changed much since its humble origins in the 1850s.
With corrugated packaging, two sheets of flat paper known as liners or linerboard, are glued to a corrugated inner material called fluting.
Together, these distinctive layers are stronger than they would be if they were used separately. If you look closely at corrugating packaging, you can see a type of weave pattern. This is what adds structure and stability to the packaging.
Different fluting can be used to make different sizes of arch in the material, creating an end result that is structurally superior to many other types of packaging and is a great option for products that need to be handled and packed carefully.
Curious for more details? We dive deeper into the corrugated packaging process and different flute grades in our ultimate guide to corrugated packaging.
Why Use Corrugated Packaging?
There are several reasons why you might consider using corrugated packaging as your product packaging of choice:
Stronger than Cardboard:
Safe, sturdy and protective,
corrugated boxes
are stronger than cardboard, so you can feel confident that whatever you put inside will stay safe and sound. Corrugated packaging is also crush and pressure-resistant.
A Wide Range of Sizes:
Corrugated packaging is available in a wide range of sizes. Although it’s strong, it’s also lightweight, making it a great fit for nearly any type of product that needs to be protected, but without the added weight.
Can Be Broken Down and Reused:
Corrugated boxes can be broken down and stored easily or transported without affecting the structural integrity of the packaging.
Good for the Environment:
The packaging material itself is made from recycled and renewable materials, such as Kraft , making them an
eco-friendly packaging option
that consumers will appreciate.
Corrugated vs. Cardboard Packaging: What’s the Difference?
With the incredible surge in online shopping (COVID19 notwithstanding), customers expect their packages to be delivered safe and sound, with the contents in good condition.
Packages that arrive damaged, crushed, or torn open leave a bad impression when unboxing. That’s why it’s so important to consider what level of strength and stability you need in your packaging.
Corrugated packaging and cardboard packaging are two of the most popular types of boxes, but it’s important to understand the difference between them so you can decide on the right balance of protection for the product inside.
Cardboard Packaging
Cardboard, also known as carton packaging, is made from thick paper or paper pulp which is then crafted into small packages or even material to help bolster the structure of lesser materials so that the contents won’t lose their shape.
Cardboard is inexpensive and easy to use as part of most shipping strategies, but it also may need additional packing material to keep the contents safe from being crushed, or being damaged by the elements.
Corrugated Cartons
These are made up of several layers of material that are stronger together than they would be on their own. An inside liner and an outside liner are filled in the middle with a fluted material that helps solidify and strengthen the entire piece.
Corrugated cartons perfectly balance strength and lightness of weight, so they’re perfect if you need to ship a variety of products carefully. In addition to their structural strength, they’re also resistant to moisture and sudden changes in temperature.
Of course, no container is fully impervious to being crushed or being exposed to rain, sleet or heat for a long period of time, but if you want the added confidence that your product will arrive securely, corrugated packaging is a great option.
When To Use Corrugated Packaging
Corrugated packaging is best for products that need to be transported from a warehouse, to a processing center and onto a delivery vehicle. With so many people and machines handling the package, it needs to withstand being shuffled, slid, tossed and even dropped. If you want to add in an extra barrier of protection, you can wrap the interior product with additional cushioning for added security and peace of mind.
Corrugated boxes are also a great choice if you want full customization control over your packaging design. You get all of the benefits of a large design area like with cardboard, except the added strength and durability. Additional features like custom opening folds, flaps, die-cuts and embossing or debossing are just a few of the many options you can add to create a unique design without worrying that the process will mar the product within.
If you’re selling food, corrugated packaging is a must. Not only is corrugated much more sustainable and hygienic, but with so many people turning to online grocery shopping and delivery, companies are choosing to insulate their corrugated packaging for even greater protection to help seal in the temperature, especially for perishable goods.
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