THE ULTIMATE CORRUGATED PACKAGING GUIDE
Cardboard is everywhere! From the boxes that deliver your online orders to the cereal you eat in the morning, cardboard is one of the most widely used packaging materials in the world. In this packaging cardboard guide we teach you everything you need to know.
CONTENTS
1. WHAT IS CARDBOARD?
2. CARDBOARD COMPOSITION
3. BOARD GRADES
4. BOX STYLES
5. SEALING
6. FLEXOGRAPHIC PRINTING
7. SUSTAINABILITY
8. MEASURING BOXES
9. STRUCTURAL CONSIDERATIONS
10.TERMINOLOGY & SYMBOLS
THE ULTIMATE CORRUGATED PACKAGING GUIDE.
Cardboard is everywhere! From the boxes that deliver your online orders to the cereal you eat in the morning, cardboard is one of the most widely used packaging materials in the world.
What exactly is cardboard? Why is it so useful? And what makes it different from regular paper?
THE ULTIMATE CORRUGATED PACKAGING GUIDE
Cardboard is everywhere! From the boxes that deliver your online orders to the cereal you eat in the morning, cardboard is one of the most widely used packaging materials in the world.
What exactly is cardboard? Why is it so useful? And what makes it different from regular paper?
CONTENTS
1. WHAT IS CORRUGATED (CARDBOARD)?
Essentially, cardboard is a strong type of paper. Cardboard is a thick, durable paper-based material made from wood pulp.
It is stronger than regular paper and comes in different types depending on how it is made and used.
CARDBOARD IS AMONG THE MOST POPULAR PACKAGING MATERIALS
ON THE ENTIRE PLANET. (AND THERE IS GOOD REASON)
PAPER BOARD (CARTON BOARD)
A single-layer thick paper used for packaging
items like cereal boxes and shoe boxes.
(Some cartons may contain micro flutes)
CORRUGATED CARDBOARD (US!)
A multi-layered cardboard with a wavy inner layer (fluting) for making
strong shipping boxes. (This is the material
that we use for all our packaging products.)
3. THE DIFFERENT BOARD GRADES
Corrugated cardboard comes in various thicknesses and strengths, categorised by board grades:
Single Face: One liner and one fluted layer (used for wrapping fragile items).
Single Wall: Two liners with a fluted layer in between (common for packaging boxes).
Double Wall: Three liners with two fluted layers (for heavier items).
Triple Wall: Four liners with three fluted layers (for industrial use).
4. BOX STYLES
FEFCO (The Federation of Corrugated Board Manufacturers) has created a standardised code system for cardboard box styles, widely used in packaging industries. The FEFCO Code helps manufacturers and customers communicate clearly about box designs.
We can manufacture all of these box styles and you can view them by clicking here to download our FEFCO guide.
5. SEALING CARDBOARD
Boxes need to be securely sealed for transport. The most common sealing methods include:
6. FLEXOGRAPHIC PRINTING
(ONE OR TWO COLOUR)
A cost effective way to add logos and branding to packaging.
packaging impacts buying decisions, increasing brand recall by 40%.
ONE COLOUR FLEXO PRINT
A cost-effective way to add logos and branding with a clean, professional finish. Ideal for high-volume orders, it ensures clear, consistent results while keeping costs low.
TWO COLOUR FLEXO PRINT
A cost-effective way to add logos and branding with a clean, professional finish. Ideal for high-volume orders, it ensures clear, consistent results while keeping costs low.
7. SUSTAINABILITY
Did you know? Cardboard’s recycling rate is at least 83.2% according to Eurostat 2022
Cardboard is an eco-friendly packaging choice, it is renewable, recyclable, and biodegradable.
Recycling it reduces waste, saves energy, and helps protect natural resources.
ACCREDITATION & COMPLIANCE
We are proud to be fully compliant with FSC,ISO, and PAS 2060 standards, ensuring sustainability, legal compliance, and customer trust while minimising and offsetting environmental impact and upholding industry best practices.
8. MEASURING BOXES
WHAT YOU NEED BEFORE YOU MEASURE YOUR BOXES
HOW TO MEASURE A BLANK SIZE.
Sometimes we may ask if you know the blank size of your original packaging. The blank size is the total width and length of the flattened box!
1. Open the Box Completely: Carefully unfold the box so it’s flat, like it was before assembly.
2. Measure the Full Width: Lay it flat and measure from one end to the other, including all flaps.
3. Measure the Full Height: Measure from top to bottom, again including all flaps.
(Here are some examples to help you know the blank size of your packaging.)
INTERIOR & EXTERIOR DIMENSIONS
IMPORTANT: Measuring from the exterior and interior if the box will give different results. When making sure
products fit inside your box correctly, you will always want to measure the interiors of your packaging.
If you measure the exterior you risk your packaging not being suitable for your product.
Exterior dimensions are used for shipping and storage.
HOW TO MEASURE A BOX
To measure a box, use the Length x Width x Height (L x W x H) format:
Length (L): The longest side of the base.
Width (W): The shorter side of the base.
Height (H): The vertical dimension from base to top.
VIDEO COMING SOON!
9. DESIGN & STRUCTURAL CONSIDERATIONS
DIE CUTTING VS REGULAR SLOTTED BOXES (RSC)
RSC Boxes: Simple design out of the, flaps meet in the center, easy to manufacture.
Die-Cut Boxes: Custom shapes, require a cutting die, used for unique designs.
STANDARD CASE
RSC Example: A Standard box - 0201 style.
DIE CUT BOX
For boxes cut by a tool called a die. Which allows for specific custom shapes and self assembly
INTERIOR FITMENTS
To protect, hold products in place and help separate different elements of a box.
LARGE FORMAT CASES
Large format Cases for the heaviest products.
STANDARD CASE
RSC Example: A Standard box - 0201 style.
INTERIOR FITMENTS
To protect, hold products in place and help separate different elements of a box.
DIE CUT BOX
For boxes cut by a tool called a die. Which allows for specific custom shapes and self assembly
LARGE FORMAT CASES
Large format Cases for the heaviest products.
FLUTE DIRECTION AND STRENGTH
Corrugated fluting refers to the wavy layer between two sheets of paperboard that gives it strength.
There are two main types: vertical and horizontal flutes.
Vertical flutes (A-flute, B-flute, C-flute): These run vertically in the cardboard, providing strength and cushioning. It’s commonly used for shipping boxes and protects items from damage.
Horizontal flutes (E-flute, F-flute): These run horizontally, offering a finer, smoother surface. They are used for packaging with a more polished finish, like retail boxes or for products with intricate designs.
WHY SWITCH FROM VERTICAL TO HORIZONTAL?
Vertical flutes are stronger, ideal for heavier items.
Horizontal flutes are thinner and smoother, better for delicate or visually appealing packaging (e.g., for display or retail).
In short, you swap depending on whether you need more strength (standard)
or a smoother, more refined surface (reverse).
Standard Flute
Stronger for stacking and best for shipping purposes
Reverse Flute (Horizontal)
Smoother printing surface and better for retail
10. GLOSSARY & SYMBOLS
General Terms
1. Box Blank – A flat piece of corrugated board that is ready to be folded into a box.
2. Bundle – A unit of multiple boxes or sheets of corrugated board held together for handling.
3. Box Style – The design or shape of the box, such as RSC (Regular Slotted Container)
4. Box Manufacturer – The company or facility responsible for producing the corrugated boxes.
Board Components
1. Flute – The wavy, arch-shaped paper sandwiched between two linerboards that gives corrugated its strength. Flute types include A, B, C, E, and F flutes.
2. Linerboard -The flat sheets of paper that make up the outer surfaces of corrugated board.
3. Medium – The wavy layer of paper (fluting) that is glued between linerboards.
4. Single Wall Board – Corrugated board with one layer of fluting and two layers of linerboard.
5. Double Wall Board – Corrugated board made of two layers of fluting and three layers of linerboard.
6. Triple Wall Board – Corrugated board with three layers of fluting and four layers of linerboard, used for extra strength.
7. ECT – (Edge Crush Test): A test measuring the stacking strength of corrugated board. It indicates the amount of force needed to crush a board when placed on its edge.
8. Bursting Test (Mullen Test) – Measures the amount of pressure the box can withstand before bursting, testing the box’s ability to handle rough handling and internal pressure.
Flute Types
1. A Flute – Thick, sturdy, and provides excellent cushioning. Flute thickness: 4.7 mm.
2. B Flute – Offers good puncture resistance and is used for smaller items. Flute thickness: 2.4 – 3.0mm.
3. C Flute – The most common flute type, good for strength and cushioning. Flute thickness: 3.5 – 4.0mm.
4. E Flute – Very thin, used for lighter packaging or retail packaging. Flute thickness: 1.2 – 2.0mm.
5. F Flute – Extremely thin, for retail packaging or delicate items. Flute thickness: 0.8 mm.
Box Styles
1. RSC (Regular Slotted Container) – The most common box style, where all flaps have the same length, and the two outer flaps meet in the center when closed.
2. HSC (Half Slotted Container) – Similar to RSC but has no top flaps.
3. FOL (Full Overlap Slotted Container) – The outer flaps overlap entirely, providing extra strength and cushioning.
4. Die-Cut Box – A box made using a die to create more complex shapes or slots than traditional boxes.
Manufacturing Terms
1. Scoring – A process where shallow lines are pressed into the corrugated board to make it easier to fold.
2. Slitting – The process of cutting corrugated board to the required size.
3. Slotting – The process of cutting notches or slots in the box, typically to form the box flaps.
4. Creasing – Creating lines on corrugated board for easier bending and folding.
5. Die Cutting – The process of cutting the box into non-standard shapes using a die.
Performance Terms
1. Stacking Strength – The maximum amount of weight a box can support without collapsing.
2. Compression Strength – The ability of a box to withstand forces applied to its top and bottom.
3. Puncture Resistance – The ability of the box to resist being pierced by sharp objects.
4. Vibration Resistance – The ability of the box to protect its contents from vibration during transport.
Other Terms
1. Stacking Strength – The maximum amount of weight a box can support without collapsing.
2. Compression Strength – The ability of a box to withstand forces applied to its top and bottom.
3. Puncture Resistance – The ability of the box to resist being pierced by sharp objects.
4. Vibration Resistance – The ability of the box to protect its contents from vibration during transport.
5. Flaps – Extension of the side wall panels that, when sealed, close the remaining openings of a box. Usually defined by one scoreline and three edges.
6. Joint -The opposite edges of the blank glued, stapled, wire stitched, or taped together to form a box.
7. Kraft – German word meaning “strength”, designating pulp, paper, or paperboard produced from wood fibers.
8. Liner – Creased fiberboard sheet inserted as a sleeve in a container and covering all side walls. Used to provide extra stacking strength or cushioning.
9. Linerboard – Flat sheets of paper that comprise the outer surfaces of a sheet of corrugated board.
10. Overlap – Design feature wherein the top and/or bottom flaps of a box do not butt, but extend one over
11. Palletizing – Securing and loading containers on pallets for shipment as a single unit load, typically for handling by mechanical equipment.
12. Panel – A “face” or “side” of a box.
13. Partition – Set of corrugated, solid fiberboard or chipboard pieces that interlock when assembled to form a number of cells into which articles may be placed for shipment.
14. Dimensions – For regular slotted containers (RSC), box dimensions are expressed as length x width x height, always using inside dimensions.
15. Length – The longest side of the box, measured along the opening (flap) of the box.
16. Width – The shorter side of the box, also measured along the opening (flap).
17. Height (Depth) – The distance between the opening and the bottom of the box, measured vertically.
18. Adhesive – Substance used to hold plies of solid fiberboard together; to hold linerboard to the tips of flutes of corrugated medium; or to hold overlapping flaps together to form the joint or to close a box.
19. Inner Flap -The shorter flaps that fold in first when closing a box.
20. Outer Flap – The longer flaps that fold over the inner flaps, often meeting or overlapping in the center.
21. Entry Panel – The side of the box where contents are inserted or accessed, typically the one with the main opening.
22. Locking – A design feature where flaps or tabs securely fit into slots to keep the box closed without tape or glue.
23. Interlocking – A closure mechanism where parts of the box fit or latch into each other for added security and structure.
24. Tabs – Small extensions that fold into slots or cutouts, often used to secure or lock the box panels in place.
GET IN TOUCH
Fill out the form or contact us using the below information.
Talk to our expert team who are always happy to help you with your cardboard box requirements
01902 496 925
sales@sandlandpackaging.co.uk
operations@sandlandpackaging.co.uk
accounts@sandlandpackaging.co.uk
