Corrugated Box

What is Corrugated Boxes ?

“Corrugated boxes are used in shipping and storage that are universal across thousands of industries. Even though people often refer to them by mistake as cardboard boxes, they are made of corrugated materials. Most typically the corrugated–meaning fluted, rippled or ridged—material from which they are made is corrugated fiberboard. This consists of two flat sheets sandwiched above and below a corrugated sheet in layers. ”

History of Corrugated Boxes in Brief Below:

Paper that is first invented by China many years ago. Corrugated paper materials have been using as packaging for 140 years. Before that time, paper products were simply too expensive due to the laborious processes by which they were made, most often by hand. With the arrival of industrial revolution processing of machinery, paper packaging materials became more and more affordable and widely used. This occurred in the Midvale of 19th century. At first corrugated boxes were mainly used to package fragile items such as ceramics, glass products and the like. But in time, more and more products, such as produce from farms, came to be shipped in corrugated fiberboard containers. By the 1990s, in the U.S. alone, manufacturers produced 25 million tons of corrugated fiberboard. Paper, once an expensive and hardly used material, had become widespread because of its affordability, strength and durability.

Making of Corrugated Boxes in Brief Below:

Today, corrugated boxes are typically made from kraft paper, a high quality paperboard derived from wood. When an even stronger is required they can be made from corrugated plastic. Paper mills produce kraft paper and sell to corrugation plants/factories. To make kraft paper, mills use recycled paper, sawdust and wood chips, which are bound together to produce heavy-duty paper using an adhesive, pressure and heat. Pine trees are the raw materials used to manufacture kraft paper and corrugated boxes. Therefore, many large manufacturers own not only paper mills, but also vast tracts of pine forest consisting of hundreds or thousands of acres. After many process the paper mills output reels of kraft paper, which are shipped to corrugating plants and stored as inventory. Manufacturers use huge machines called corrugators, which can be 400 feet long, to corrugate the kraft paper. First, these machines soften the kraft paper in preheating rollers at high pressure and humidity, making it easier to form the flutes or ripples. Then corrugated molds are pressed into the cardboard to form the fluted board. Two glue stations next join this newly corrugated material to the outer flat layers using a corn starch-based adhesive, making a complete piece of corrugated fiberboard. After drying this material over hot, steamy pates, the surface may be sanded smooth and in some cases coated with a waterproof, glossy finish. Finally, the massive corrugator machine divides the continuous fiberboard into box blanks, large sheets ready to be cut into different sizes. Many of the corrugator machines manufacturers’ use can produce 600 feet per minute of corrugated fiberboard. The sides of corrugated boxes are composed of layers of materials: an inner layer, a middle layer, and an outer layer. The middle layer is fluted with wave-shaped arches that act as support and cushioning for the materials inside the box. Box making machines then produce actual boxes from this corrugated fiberboard, which are sold typically in bulk bundles of 30-60 or more. To save space during shipping the bundled boxes are sold flat rather than assembled into box form. These durable fiberboard boxes are used by many industries

Corrugated Box Benefits

There are many advantages to using corrugated boxes. They can be recycled; are cheap price and lightweight; are everlasting and multilateral; are a reliable way to ship goods and protect them in transit; and they provide an ideal surface on which to print text and graphics. There are, however, downsides to corrugated boxes. These boxes cannot be used to ship heavier items, and in some industries where sanitary concerns are paramount, such as medical supplies and hospital food storage, fear of contamination from insect infestation and liquid absorption preclude the use of corrugated fiberboard containers. Due to Lockdowns and social-distancing norms set off a surge in online shopping. Many start-ups who wish to take advantage of this trend turn to boxes and paper bags to deliver their products. This packaging not only serves as protection but also as branding, establishing trust between consumer and producer. Proper packaging design helps build an identity for a product. Some things are below explain in which boxes are used:-
Food Industry – Corrugated boxes are made from natural materials. The glue used to connect their parts is made from starch and water. These boxes also protect contents from bacteria, keeping foods fresher longer.
E-commerce – Rising global demands for convenient and lightweight packaging solutions have made corrugated boxes an irreplaceable asset in the e-commerce industry. They offer security and safety for the many products that pass through far-off trade routes and supply chains.
Electronics – Electronics and electronic components need to be handled with care. Corrugated boxes can be supplemented with protective packaging materials to keep these types of items from damage, thanks to the cushioning provided by their fluted layers.
Textile – The textile industry is very reliant on branding to ensure that customers will return to purchase their products. Corrugated boxes allow manufacturers to design and personalize their packaging to attract and retain customers.


Compliance, Care and Safety of Corrugated Boxes :


Keeping corrugated boxes dry is essential to maintain their strength and durability, as moisture undermines these fundamental properties. Also, like wood that is easier to split along the grain, corrugated boxes made of fiberboard are directionally dependent. They will not function properly if handled in a manner inconsistent with their intended anisotropy or directionality. Things to Evaluate for Choosing the best Manufacturer of Corrugated Box In India there are many manufacturers of corrugated boxes in different different states. It is therefore key to find the right one for your specific needs. Discuss with potential suppliers: whether they have been certified; manufacturing timelines; how they will ship your boxes to you; the end use for which you need the products; and if they are able to develop the custom solutions you need, such as printing text and graphics on the boxes, any unusual shapes or sizes you may need, dividers and custom finishes such as waxed corrugated boxes. Additional things to evaluate include whether the packaging will enhance your company’s brand; whether you should measure the boxes internally (for shipping products to customers) or externally (for in-house uses); box strength (which is based on the grade of kraft paper used to manufacture the box); and the level of product security you require.

Corrugated Box Plants – A factory that produces corrugated and/or cardboard boxes.

Converting Machines – Convert flat corrugated boards into boxes. Machine types may include cutter, rotary, die cutters and stretching. Corrugated Paperboard – Two sheets of stiff paper joined by a middle sheet of pleated paper. Corrugating Medium – The wavy “fluted” paper inside the corrugated paperboard. Corrugating Rolls – Gear-like cylinders that shape paper into a series of waves or “flutes”. Die-cut Machines – These are machines that cut the corrugated board into a pattern that will later be folded into a box shape.


Flute size: : Corrugated boxes are available in several different flute sizes, which affect their strength and cushioning ability. The most common flute sizes are A, B, C, E, and F, with A being the smallest and F being the largest.
Board thickness: Corrugated boxes are available in different thicknesses, typically measured in points or millimeters. The thickness of the board can affect its strength and rigidity.
Board material : : Corrugated boxes are typically made from recycled paper or other fibers, which can affect their strength, durability, and environmental impact.
Box style : Corrugated boxes can come in a variety of styles, including regular slotted containers (RSC), half-slotted containers (HSC), full-overlap containers (FOL), and more.
Box size : Corrugated boxes can be customized to fit specific applications, with sizes ranging from small boxes for retail products to large boxes for shipping large items.
Printing and labeling : Corrugated boxes can be customized with printing and labeling to include branding, instructions, and other information.