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Corrugated Packaging

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What are corrugated Boxes?


Corrugated boxes, more specifically known as ‘corrugated fiberboard boxes’, are made of corrugated stock.  These boxes are strong, durable and offer higher damage, shock and compression resistance as compared to regular carboard boxes.  In addition, corrugated boxes are a cost-effective and weight efficient shipping alternative to plastic, wooden or metal cases.


What does the term 'flute' refer to in the context of corrugated packaging?


Corrugated stock is manufactured by gluing together two sheets of flat paperboard, typically referred to as linerboard, on either side of a wavy-shaped 'corrugation medium'. This wavy-shaped medium is often referred to as 'flute'. The flute is what gives corrugated fiberboard its strength and structure. Flute is available in multiple thickness options, such as B-flute and E-flute, depending on the specific strength and durability requirements.

The wavy-pattern of the flute often tends to be slightly visible on corrugated packaging as a series of parallel lines. The visibility of this pattern can be minimized by using a thicker cardboard instead of linerboard during the corrugation manufacturing process. Please make sure to communicate any such visual or aesthetic requirements to your account manager at the time of getting a price quote for your specific project.


What do the terms 3-ply corrugated stock and 5-ply corrugated stock refer to?


3-ply corrugated stock has a sheet of flute glued in between two sheets of paperboard.  This is also known as ‘single wall corrugated stock’ and is most commonly used for making cost-effective corrugated boxes and inserts.  On the other hand, 5-ply corrugated stock has two sheets of flute alternatively layered between three sheets of linerboard.  Also known as ‘double wall corrugated stock’, this version of corrugated stock is sturdier and specifically used for heavier products.


Are corrugated boxes always brown?


No, the inside as well as the outside of the corrugated boxes can be brown or white. You can also choose the boxes to be white on inside and brown on the outside and vice versa.


How should I measure the dimensions of corrugated boxes?


In general, all boxes and especially corrugated boxes are measured from the inside.  Inside dimensions are recommended because the corrugated board thickness can vary.  For example, a box made of B-flute will not have the same outer dimensions as a box made from E-flute.  With the box open toward you, here is how to get the correct measurements for the inside of the box:

  • The length is measured from the inside edge on the left to the inside edge of the right side of the box.
  • The width is measured from the front inside edge to the back inside edge of the box.
  • The height is measured from the top inside edge to the bottom inside edge of the box.


Can you send me samples of your custom corrugated packaging?


We can send samples of our recent print orders.  Please submit a sample request and our sales representative will be in touch so that appropriate corrugated box samples can be sent.


Is white considered a printing colour?


The simple answer is that it depends. White colour is typically not considered a separate colour for most orders. As white is typically the default colour of the underlying paper, it is simply recognized as the absence of any ink and thus not considered as a printed colour. On the other hand, in the case of corrugated boxes, white may be considered a printed colour if the target surface is brown. In short, when using coloured paper for particular projects, white ink may be used if any text or graphic requires it.


What styles or types of corrugated boxes can Printingblue produce?


We can produce many different standard styles of corrugated boxes. In addition, we can also produce customised boxes to fit your specific requirements. Please send us the details and we will be happy to produce a free mockup for your review. Here is a list of some of the many different corrugated packaging that we can produce:


Are these corrugated boxes suitable for shipping and transportation within Canada using FedEx, UPS, and Canada Post?


Yes, these corrugated boxes are suitable for transportation and shipping. They are carefully crafted to be sturdy and dependable, ensuring your items arrive safely and intact. Our boxes are built to withstand the rigors of transportation and provide the necessary protection and structural integrity for worry-free shipping.

Material Shipping Boxes: White or Brown Corrugated Stock or Forte
Material Thickness Corrugated Stock: 3-ply corrugated
Finishing Types Lamination: Gloss, Matte, Sandy Matte, Soft Touch, Pattern
Coating: Gloss AQ, Satin, Varnish, Spot UV, Flood UV
Features Foil Stamping
Die Cutting
Metallic Inks
Custom Size
Other Options Window Cutouts
Ribbons and Handles
Hang Tab
Scoring and Gluing
Custom Perforation
SKU# RP-014

Strength and Versatility of Corrugated Boxes: An Essential Packaging Solution

Corrugated boxes are a specific type of packaging made from corrugated material which is in turn constructed by layering a fluted (ridged) sheet between two flat liner-board sheets. This layering creates a rigid and sturdy structure. The wavy fluted material sandwiched between the two flat paperboard or liner-board sheets is commonly referred to as 'corrugated flute'. There are several types of corrugated flute, including:

  • A-Flute: A-flute is the thickest type of corrugated flute. A-flute offers excellent stacking strength, cushioning, and insulation properties, making it suitable for fragile or heavy products.
  • B-Flute: B-flute has a smaller flute size than A-flute. It provides good structural rigidity and stacking strength while offering a smooth printing surface. It is commonly used for shipping boxes and large point-of-purchase packaging.
  • C-Flute: It has a medium-sized flute. It strikes a balance between stacking strength, cushioning, and printability. It is versatile and widely used for packaging and shipping applications across various industries.
  • E-Flute: It is thinner than B or C flutes, offering a smooth surface and excellent printability. E-flute is most commonly used and provides a more compact and lightweight option for packaging items including cosmetics, electronics, counter displays, or other delicate products.
  • F-Flute: It is the thinnest flute available, providing a smooth surface for printing and excellent flexibility. F-flute offers a premium and compact packaging option, often used for high-end consumer goods or small retail products.

In addition to offering additional strength, corrugated boxes also offer versatility as they are available in various sizes and shapes to cater to different packaging needs and meet the requirements of Canada Post and other common carriers. Furthermore, the lightweight nature of corrugated flute contributes to reduced shipping costs. As corrugated flute is often manufactured using recyclable materials, it is both cost-effective and eco-friendly. These boxes can also be customised and printed with logos and information, enhancing brand visibility.

Tips To Create Unique and Attractive Corrugated Packaging

To make your custom corrugated packaging more attractive, you can utilize several features and techniques, including:

  • Custom Shapes: Deviate from the standard rectangular box shape and opt for custom shapes that align with your brand or product. Custom-shaped boxes instantly grab attention and create a memorable packaging experience.
  • Innovative Structures: Explore innovative box structures with a unique opening or closing mechanism. Think of origami-inspired folds, pull-out drawers, or interactive elements that surprise and engage customers.
  • Special Finishes: Apply foil stamping or UV coating to certain areas of the packaging design to add a unique and premium finish and enhance the visual appeal. It can make colours appear more vibrant and create a premium look.
  • Die-cut Windows: Incorporate a die-cut window in the packaging design to showcase the product inside. Windowed boxes allow customers to see the product and create a visually engaging experience.
  • Colourful Logos and Artwork: Use colourful logos and artwork that align with your brand identity to create a visually appealing packaging design. Vibrant and eye-catching colours can attract attention and make your packaging stand out.
  • Text on the Inside Cover: Add a personalized touch by placing text on the inside of the cover. It can be a welcoming message to new customers or provide product information in order to create a positive and informative unboxing experience.

In addition to custom printing techniques, several accessories can also be used in combination with corrugated packaging to enhance functionality and provide additional protection. Standard accessories include:

  • Inserts and Dividers: Packaging inserts and Dividers are used to separate and secure individual items within a corrugated box. These inserts prevent shifting or damage during transit and provide added protection for fragile or delicate products.
  • Foam Cushioning: Foam inserts or padding can be used to provide cushioning and shock absorption within the box. It helps protect fragile or sensitive items from impact or vibration during transportation.
  • Labels: Labels are used to provide important information such as product details, handling instructions, or barcodes. These labels can be attached to the outside of the corrugated packaging for easy identification and scanning.
  • Pallets and Stretch Wrap: Pallets are used to stack and transport multiple corrugated boxes. Stretch or shrink wrap is applied around the palletized boxes to secure them together and provide additional stability during transportation.

Sustainable Shipping: The Role of Corrugated Boxes in the E-Commerce Industry

Corrugated boxes play a vital role in the e-commerce industry as they are the primary packaging solution for shipping to customers. E-commerce-oriented boxes and packaging provide protection against handling, stacking, and transportation hazards, safeguarding products from damage during transit. These boxes are cost-effective, lightweight, and easy to handle, making them an ideal choice for efficient fulfillment and shipping. The customisable nature of corrugated packaging allows businesses to incorporate branding elements and product information which enhances the overall customer experience. Additionally, since corrugated boxes are eco-friendly and recyclable, their use aligns with the sustainability goals of many e-commerce-based companies.

Corrugated Board Types:

Custom product and shipping boxes manufactured using corrugated paperboard are commonly referred to as corrugated boxes. Corrugated paperboard is composed of rows of paper columns that are commonly referred to as fluting. The fluting layer contains air pockets that provide additional protective cushioning for any packaged products. The fluting layer is combined with a paper liner layer to create the corrugated paperboard material. The combination of the fluting and the liner layers makes corrugated board significantly stronger than ordinary cardboard.

Common types of corrugation, providing varying degrees of protective capability, are referred to as:

  • Single Face Board
  • Single Wall Board
  • Double Wall Board
  • Triple Wall Board
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