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About Corrugated Boxes

Corrugated boxes are constructed of corrugated paperboard, which consist of two sheets of paper board glued to a middle layer of paper with ridged “flutes”. Flutes, similar to pleating, contain air, which acts as a strong cushion. The paper flutes also reinforce the material to make it stronger. Corrugated paper was patented in 1856, but corrugated boxboard wasn’t used as a shipping material until much later. In 1890, the first corrugated box, similar to those manufactured today, was developed. The new box was flat, pre-cut, could be folded into a box and was manufactured in bulk.

To manufacture corrugated boxes, box manufacturers use high-precision corrugators which can produce 500 feet of corrugated paper board per minute. The paper board is humidified to soften it, making it easier to form the flutes. After the fluted board is formed, the paper must dry over hot plates. The fluted paper is then adhered to the outer paper with a starch-based adhesive. Another layer of outer paper is adhered to the other side of the fluted paper, which is now sandwiched between the outer paper board layers. Once the corrugated material is formed, it can be folded, pressed and cut into shapes that can be folded to create a box.

Corrugated boxes come in many varieties and sizes, depending on how they will be used. Working with their customer, corrugated box manufacturers can create custom printed corrugated boxes, corrugated boxes with dividers, waxed corrugated boxes and many more sizes and styles. Specialty corrugated boxes are an ideal solution to many storage, handling and shipping requirements.

Corrugated boxes are one of the least expensive containers ever created. The cost to produce, fill and ship the containers is low and the materials used to make corrugated boxes are inexpensive. Corrugated boxes can also be recycled, making them very appealing in today’s environmentally-concerned industries. Over 70 % of corrugated material is recovered, recycled and made into new corrugated boxes and other products. In 2006 alone, 25.2 million tons of corrugated material was recycled.

Featured Articles

“Why Corrugated?”
http://www.corrugated.org/Basics/WhyCorrugated.aspx

“Cardboard Recycling”
http://www.green-networld.com/tips/cardboard.htm

“How are Corrugated Boxes Made?”
http://www.tappi.org/paperu/all_about_paper/earth_answers/EarthAnswers_HowBoxes.pdf

Types of Corrugated Boxes

• Brown cardboard boxes are the most commonly colored box. Boxes may also be white, colored or pre-printed.
  
• Cardboard boxes are made from any heavy paper-pulp based material. They are not necessarily corrugated.
  
• Corrugated cartons are specially designed containers made to fit a specific product. Cartons have a lid which can be opened and re-closed easily.
  
• Corrugated plastic boxes are formed from extruded plastic. The corrugated plastic has a similar appearance to that of corrugated paper board.
  
• Corrugated shipping boxes are made to ship items via mail, ground or air transport. They are often specially marked and must conform to certain handling requirements.
  
• Corrugated trays are often used for display purposes or used with a shrink-wrap covering.
  
• Five panel folder boxes are shipped flat without any folding joints. The box has five long panels, one of which fully overlaps. The ends also fully overlap.
  
• Folding boxes can be taken apart and re-folded numerous times. Folding boxes save storage space.
  
• Full overlap boxes are made with the major flaps fully overlapping, increasing the stability of the seal.
  
• Full telescope boxes have two telescoping sections. The sections may be formed using staples, die-cut locks or adhesive.
  
• Partial telescope boxes have two sections. The top telescopes partially over the bottom.