E-commerce businesses are booming, and so is the packaging that is required to deliver e-commerce products. Among the several types of packaging materials used to manufacture shipping boxes, custom corrugated boxes are at the top. The main reason for this is that corrugated material is shock-absorbent and lightweight. So brands that do not want to deliver a damaged product and also need low shipping costs can opt for this packaging paper.
From double to triple and so on, there are several types of corrugated material. Brands can choose what is required for their product protection. From A to F, there are so many flute styles available in the market. You can also select boxes with the logo of your brand and use the packaging as a walking housing of your brand.
Durability of Corrugated Material
Unlike polyboard and chipboard, corrugated material is strong against crushing and has cushioning properties. The fluted inner layer is sandwiched between flat linerboards that enhance the shock-absorbing properties. Corrugated packaging meets a wide range of applications depending on:
- The type of flute
- Board grad
- Wall construction
- Supports stacking capabilities
- Protects products from compression, accommodates routine transportation
Purpose of Flutes in Corrugated Materials
Flutes are the ridged paper layers inserted between smooth linerboards in corrugated material. They give:
- Cushioning
- Increase structural rigidity
- Prevent crushing during transportation and storage
The flute size impacts board thickness and stacking strength. You can also see a visible impact on print quality and flexibility. With the right flute, you can align packaging performance with minimal product weight and maximum protection.
A-Flute
One of the thicker corrugated flute profiles, A-flute has great cushioning and comparatively high impact resistance. Its comparatively large waves have a way of creating space in which they absorb shocks to deliver the goods. This flute is not only good for delicate goods but also for protective packaging and applications needing extra cushioning. But it does have a thicker structure and thus can make some exterior printing less even than finer flute profiles.
B-Flute
It delivers an organized body structure, balancing solid crush resistance combined with a strong surface suited for packing. You often find this type of material in retail and die-cut packaging designs. Its thinner form factor enables easy storage and converting features. This flute type offers protection from rough handling. B-flute also matches well with multiple print processes and is appropriate for branded packaging applications.
C-Flute
This is the medium-strength type and achieves a balance of cushioning and overall thickness. C-flute has a lot of applications in household goods and glassware. The fluted form aids in absorbing blows, while also being rigid enough for stacking and transport. C-flute is a more reasonable alternative for businesses looking to minimize the risk of product damage without stepping up to heavier double-wall construction.
E-Flute
For a finer corrugated configuration with a smoother finish E flite is the best. It allows for better printing and visual display in stores. Often used for cosmetics boxes and pizza slice boxes. The compact build offers various cushioning and stiffness while minimizing package thickness. E-flute is especially useful when the economy of corrugated board combined with high-quality graphics and lightweight storage are needed for business use.
F-Flute
It has a narrow channel that is used for neat packing, and it also has a smoother surface for printing. F-flute uses 30% less material than B and C flutes. It is frequently used with cosmetics and specialty food packaging. The thinner structure is better capable of reducing package volume while maintaining useful rigidity. F-flute does provide less cushioning than the thicker profiles but is a good option if the product must not only look great but also be lightweight and fit into tight boxes.
G-Flute
When extra fine packaging is required then G-flute is the best option. It has a smooth surface with small flutes, which is excellent for lightweight product packaging and small retail cartons. Before going for G-flute in any particular packaging application, businesses should evaluate board strength based on crease quality. This helps in converting compatibility and the printing requirement.
N-Flute
It is a very thin flute type for lightweight packaging with smooth printed surfaces. N flute has a small wave form that lends to a thick board that is less noticeable than larger flute profiles with surface variations. It could be adapted to specific retail and specialty packaging markets, based on local aerospace lifecycle supply chains. Check with your corrugated board supplier for the availability and performance specifications before ordering.
BC Double-Wall Construction
The BC double-wall board features layers of B-flute and C-flute sandwiched between layers of the material in a multi-layer corrugated configuration. This type of construction provides more thickness and stacking strength than a typical single-wall board. Suitable for heavier loads and goods that are expected to be packaged more efficiently in transport. The protective performance of the boxes is determined by:
- Flute combination
- Linerboard grades
- Future specs
- Adhesives
- Box sizes
EB Double-Wall Construction
As a combination of E-flute and B-flute, the EB double-wall board achieves an adequate degree of surface smoothness. This smoothness is needed for printing as well as improved barriers to meet strict structural demands. It can be ideal for retail packaging, and high end shipping boxes.
Styles of Corrugated Boxes
Different types of cardboard boxes are available, and different styles of boxes for different products can be used in the form of corrugated boxes. With slotted containers known for their versatility, die-cut boxes come with a defined shape and exact closure options. Mailer boxes are designed automatically for the e-commerce delivery process. Some box styles are as follows:
| Packaging Type | Main Purpose | Key Feature | Common Products | Business Benefit |
| Shipping Boxes | Product Protection | Strong Construction | Shipped Goods | Reduced Damage |
| Mailer Boxes | Online Delivery | Secure Closure | Retail Orders | Better Branding |
| Display Boxes | Product Presentation | Easy Access | Store Products | Increased Visibility |
| Food Packaging | Safe Transport | Ventilation Holes | Fresh Produce | Product Freshness |
| Electronics Packaging | Device Protection | Protective Inserts | Electronic Devices | Safer Shipping |
| Gift Packaging | Premium Presentation | Decorative Finishes | Gift Sets | Brand Appeal |
| Industrial Packaging | Heavy Transport | Reinforced Structure | Machine Parts | Load Stability |
How We Improve Print Vibrancy on Corrugated Material
To print vibrantly on corrugated paper, we start with the correct linerboard. The linerboards consist of an even surface. White coated liners enable colours to look brighter than unbleached kraft paper surfaces. Printing methods and inks also impact the overall quality of the bo design. We apply primers and coatings to give high quality and scuff-resistance to the artwork. Our company makes sure to give you boxes that provide commercial consistency and high packaging via the following printing processes:
- Flexographic Printing
- Digital Printing
- Offset Printing
- Screen Printing
- Preprint Flexography
- Litho-Lamination
- UV Printing
Coatings and Add-Ons on Corrugated Material
Coatings and add-ons enhance various features in corrugated packaging, like protecting surfaces and facilitating easier handling. We apply coatings on the material surface or incorporate them within. From gloss to matte, there are several options. Different coatings have different appearances and costs, which can be discussed with our designers.
These may be additional packaging features included in the box design. Add-ons enable a better user experience and product showcase. You can also enhance the market value of your product by investing in custom add-ons for your boxes. Our add-ons and coating options are mentioned in the table:
| Coating | Main Purpose | Add-On | Main Purpose |
| Gloss coating | Enhances shine | Custom inserts | Secure products |
| Matte coating | Reduces glare | Internal dividers | Separate items |
| Aqueous coating | Adds protection | Die-cut handles | Improve carrying |
| UV coating | Improves finish | Display windows | Showcase products |
| Soft-touch coating | Creates texture | Tear strips | Simplify opening |
| Varnish coating | Provides protection | Security seals | Indicate tampering |
| Anti-scuff coating | Reduces abrasion | Corner protectors | Reinforce edges |
| Grease-resistant coating | Limits grease | Protective cushioning | Absorb impacts |
| Water-resistant coating | Resists moisture | Custom labels | Display information |
| Barrier coating | Limits penetration | Locking closures | Secure packaging |
Order Boxes by Wax Papers Co.
Interested in corrugated boxes that do double duty, as both product protection and brand reinforcement? Wax Papers Co. aims to make custom packaging designed around the dimensions of the product you need boxes for, the material and printing preferences you prefer, as well as finishing options. From shipping cartons and e-commerce mailers to retail and promotional packaging, the right combination of board strength and custom features is what makes it work for your business. Get in touch with Wax Papers Co. to share your packaging needs and discover customized corrugated box solutions for your brand.
