Understanding Corrugated Boxes: Types and Benefits

If you haven’t started using corrugated boxes for your packaging yet, consider this your wake-up call. The packaging you choose could be the difference between a product arriving safely to your customer or facing damage that leads to costly returns, customer dissatisfaction, and potential damage to your reputation.

With the rise of e-commerce and faster delivery expectations, businesses are pressured to get packaging right. In 2024, the Asia Pacific region led the global market with a 35.14% share, showing how essential strong, reliable packaging is for success in today’s fast-paced market. Corrugated boxes are a key solution that can help prevent the headaches of damaged goods and improve overall customer experience.

If you’re still relying on packaging that doesn’t offer enough protection, it’s time to rethink your strategy. Corrugated boxes are built to protect your products during transit and keep your customers happy. Whether in retail, manufacturing, or e-commerce, choosing the right packaging can save money, improve shipping efficiency, and prevent unnecessary returns.

In this blog, we’ll explore what corrugated boxes are, the available types, and their numerous benefits to your business. By the end, you’ll understand why investing in this type of packaging is smart for protecting your products and growing your brand. Let’s get started!

What is a Corrugated Box?

A corrugated box is an essential packaging solution made from a unique structure of materials designed to provide vital protection for products during storage and transportation. Here's a breakdown of how it works:

Structure: A corrugated box is made of many layers:

Fluted Layer: The middle wavy or "fluted" layer offers cushioning and rigidity. This layer absorbs shocks, ensuring that products inside are protected from impacts and rough handling.
Outer Layers: The two flat outer layers, typically made from strong paperboard, provide additional strength and help the box maintain its form under pressure.

Product Safety, Cost Efficiency, and Lightweight Protection: Corrugated boxes are designed with the primary focus on protecting products during storage and transportation. The fluted layer inside provides cushioning that absorbs shocks, safeguarding items from impacts and rough handling. Not only are they effective at ensuring product safety, but they are also a cost-efficient solution due to their lightweight structure, reducing overall shipping costs.

Versatility and Customization: Corrugated boxes come in various sizes, strengths, and designs, customised to suit different product types. Whether you need:

Lightweight protection for electronics or apparel.
Heavy-duty packaging for machinery and industrial goods.
Temperature-sensitive solutions for food or pharmaceuticals, designed to maintain the correct environment during transit.

There’s a corrugated box solution customized to your requirements. For temperature sensitive packaging, standards and guidelines can be found in the FEFCO Code, which ensures optimal protection for perishable goods.

Eco-Friendly: Corrugated boxes are recyclable and made from sustainable materials, making them an environmentally friendly choice. Using corrugated packaging is a responsible and effective solution for businesses aiming to reduce their carbon footprint while maintaining product integrity.

Now that we have a clear understanding of what a corrugated box is, let's explore how it’s used across various industries and why it’s such a popular choice for businesses worldwide.

Applications of Corrugated Boxes in Business

Corrugated boxes are more than just protective packaging. They are an indispensable tool in a variety of business operations. From e-commerce to industrial packaging, their versatility and reliability make them a key part of numerous industries. Here’s how they are used across different sectors, specifically highlighting industries that benefit from corrugated boxes:

1. E-Commerce and Retail

By 2024, over 270 million Indians were shopping online, making India the second-largest e-retail market in terms of online shoppers, surpassing the United States. The growing demand for online shopping has made corrugated boxes the preferred choice for shipping products directly to customers. Their ability to provide protection and branding opportunities is invaluable for businesses in the e-commerce space. Companies in the Manufacturing Enterprises Using Corrugated Packaging, especially in FMCG, electronics, and retail, utilize these boxes to ensure their products arrive intact while enhancing the brand’s presence.

2. Food Industry

In the food sector, corrugated boxes are essential for transporting perishable goods, such as fresh produce and packaged food. These boxes offer protection against moisture, bacteria, and temperature changes, ensuring that products remain fresh during transit. The strength and cushioning of corrugated boxes make them ideal for safeguarding delicate food items, reducing the risk of damage or spoilage.

Corrugated boxes are also an eco-friendly choice, as they are fully recyclable, aligning with the increasing demand for sustainable packaging solutions. By using corrugated boxes, food businesses can improve product safety while enhancing their environmental responsibility.

3. Electronics and Fragile Items

When shipping delicate products such as electronics, the packaging must ensure maximum protection against shocks, abrasions, and rough handling. Corrugated boxes are perfect for providing the necessary cushioning to prevent damage. Packaging & Printing Companies working with the electronics industry take advantage of the durability of corrugated boxes, offering customized packaging solutions that cater specifically to the protection of sensitive components.

4. Textiles and Apparel

The rise in online shopping has driven an increased need for corrugated boxes in the textile industry. These boxes offer safe, reliable, and customizable packaging that ensures garments and accessories are delivered without damage. Businesses in this sector benefit from lightweight packaging solutions that reflect their brand while maintaining product integrity during shipping.

5. Healthcare and Pharmaceuticals

In the healthcare sector, corrugated boxes are crucial for transporting medical supplies, pharmaceuticals, and sensitive equipment. These boxes are designed to meet strict safety and hygiene standards, offering protection against damage during transit. Additionally, they can be customized to meet the specific needs of the healthcare industry, providing tailored solutions that maintain the integrity of sensitive materials. Corrugated boxes also offer low-cost packaging options, making them an affordable choice for pharmaceutical companies that need reliable and cost-effective solutions for shipping their products safely.

6. Automotive and Industrial Packaging

For the automotive industry, corrugated boxes are a practical solution for shipping and storing auto parts. By using higher GSM (grams per square meter) paper, these boxes offer enhanced strength while maintaining a lightweight transport method. This ensures that even larger and heavier auto components are safely packed and protected during long-distance transport. Corrugated boxes also provide customizable packaging options, allowing businesses to design packaging that meets the specific needs of various auto components, offering both safety and efficiency at a low cost.

7. Publishing

In the publishing industry, corrugated boxes are used to ship large volumes of printed materials, such as books, magazines, and documents. The weight and moisture concerns associated with printed items are addressed by using triple-ply corrugated boxes that offer additional protection against environmental factors. Publishing houses rely on durable and cost-effective packaging solutions to ensure their products arrive intact.

Improve your business operations with sustainable and customizable corrugated packaging solutions tailored to your industry needs. Visit sbinfo.tech/correx now to learn more!

Many of us confuse corrugated boxes with cardboard, but they are actually quite different. To truly understand the value of corrugated boxes, let's first take a look at how they differ from cardboard and what makes them stand out as a packaging choice.

Corrugated Box vs. Cardboard

While "cardboard" and "corrugated box" are often used interchangeably, they have distinct differences that make each suitable for specific tasks. Understanding these differences can help businesses choose the right material for their packaging needs. Essentially, the main distinction lies in the structure and strength of each material, as well as how they perform under pressure.

What Sets Them Apart?

Corrugated boxes are made by layering a fluted sheet of paper between two flat sheets, providing both strength and durability. This fluted design acts as a cushion, making them perfect for protecting fragile items during transit.
Cardboard, on the other hand, is made from a single, thick paperboard layer. While sturdy, it lacks the cushioning properties of corrugated boxes, making it better suited for lighter applications or items that don’t require extra protection.

Now, let's take a closer look at the key differences between the two:

Feature	Corrugated Box	Cardboard
Structure	Made from a fluted sheet of paper between two flat sheets.	Typically made of a single, thick paperboard layer.
Strength	Strong and durable, able to withstand pressure and impact.	Less durable and prone to bending or breaking easily.
Protection	Offers superior protection against damage during transit.	Provides basic protection but lacks shock absorption.
Weight	Lightweight yet strong, making it ideal for shipping.	Heavier than corrugated boxes and less efficient for shipping.
Recyclability	Fully recyclable and eco-friendly.	Also recyclable but often used for lighter packaging.
Common Uses	Shipping, heavy-duty packaging, and protecting fragile goods.	Typically used for display boxes, arts and crafts, and lighter packaging needs.

By understanding these differences, businesses can select the material best suited for their products. Now that we've looked at the distinctions between corrugated boxes and cardboard, let's explore the benefits that corrugated boxes bring to the business.

Benefits of Using Corrugated Boxes

Corrugated boxes have long been the preferred choice for packaging due to their versatility, cost-effectiveness, and exceptional protection. Here’s how businesses across various sectors benefit from using corrugated boxes:

1. Superior Product Protection

Corrugated boxes are known for their ability to safeguard products from external damage during transit. The fluted design offers a shock-absorbing layer, reducing the risk of damage caused by impact or rough handling. This makes them ideal for shipping delicate items, electronics, or other fragile products.

2. Cost-Effective and Reusable

While offering premium protection, corrugated boxes remain one of the most affordable packaging options. Their lightweight design helps to reduce shipping costs, and they can be reused multiple times, further lowering overall costs. Additionally, they also align with modern environmental standards and help businesses reduce their carbon footprint.

3. Customizable and Branding Opportunities

The ability to easily customize corrugated boxes is one of their most attractive features. Companies can print logos, product details, and marketing messages directly on the boxes, enhancing brand visibility. Well-designed packaging not only protects but also acts as an additional marketing tool, creating a memorable unboxing experience for customers.

4. Sustainability

Corrugated boxes are made from renewable resources and are fully recyclable. According to the EPA, over 70% of corrugated boxes are recycled, contributing to the reduction of landfill waste. This makes them an eco-friendly choice that aligns with businesses' sustainability goals and environmental responsibility.

5. Versatile Applications Across Industries

Whether it’s shipping electronics, heavy-duty machinery, or fragile goods, corrugated boxes can be tailored to suit any product. Their strength and customization options make them ideal for a wide range of industries, including retail, food and beverage, electronics, and logistics.

With a clear understanding of the benefits corrugated boxes offer, let's now take a closer look at how these versatile boxes are made, ensuring their strength and reliability for your packaging needs.

How Corrugated Boxes Are Made?

The production of corrugated boxes is a detailed process that combines traditional work crafts with modern technology, ensuring strength, durability, and sustainability. These boxes are made from eco-friendly materials, emphasizing recyclability and minimal environmental impact. Here's a closer look at how these versatile boxes come together, step by step:

1. Pulping and Paper Production

The journey begins with turning wood pulp into paper. The pulp is cleaned and processed, then transformed into large rolls of flat paper that will form the outer layers of the corrugated box. The paper used in this process is often sourced from recycled materials, making it an environmentally friendly choice. The quality of this paper is critical to the box's final strength and durability, ensuring it can withstand the pressures of transit and storage while maintaining sustainability.

2. Fluting Process

The distinctive feature of corrugated boxes is the fluted, wavy layer that gives them both strength and flexibility. This layer is produced by passing paper through a machine that shapes it into a wave-like structure. The fluted paper is then glued between two flat sheets of paper, creating the box’s tough structure. The fluted design not only provides cushioning for fragile products but also adds rigidity, allowing the box to hold up under pressure without compromising its eco-friendly properties.

3. Cutting and Shaping

Once the paper is fluted, it’s carefully cut into the desired shapes and sizes. This process requires precision to ensure that each box fits the products it’s designed to protect. Cutting machines are equipped to create various designs, such as regular slotted containers (RSC), die-cut boxes, or custom sizes to meet specific product requirements. This adaptability makes corrugated boxes suitable for virtually any industry, from retail to industrial packaging.

4. Printing and Branding

After shaping, the outer surface of the corrugated box is printed with logos, product information, and branding elements. Many businesses take advantage of this step, turning their packaging into a powerful marketing tool. The use of water-based inks and eco-friendly printing methods ensures that the boxes remain sustainable. Not only do these boxes protect products, but they also enhance brand visibility, creating a memorable experience for the consumer before the product is even opened.

5. Assembly and Quality Control

Once printed and shaped, the boxes are folded into their final form. At this stage, they undergo rigorous quality checks to ensure they meet strength and durability standards. The boxes are carefully inspected for defects like tears, misalignments, or weaknesses. This final inspection guarantees that only high-quality boxes make it to the production line, ensuring that the products inside are safely protected during their journey.

By combining durable, recyclable paper layers with a flexible fluted interior, corrugated boxes provide a sustainable packaging solution that offers both protection and environmental responsibility. Their ability to withstand pressure, absorb shocks, and remain lightweight makes them an indispensable part of modern packaging, helping businesses balance efficiency, cost, and sustainability.

To better understand the variety of options available, let's explore the different types of corrugated boxes.

Types of Corrugated Boxes

Each type is designed with specific needs in mind, offering varying levels of protection and suitability for different products. Let's explore the types of corrugated boxes:

1. By Wall Structure

The structure of a corrugated box plays a significant role in determining its strength and suitability for various types of products. Here’s a breakdown of box types based on their wall structure:

Single-Face: This type consists of one liner and one fluted layer, often referred to as a 2-ply sheet. It is primarily used for cushioning or wrapping fragile items, providing basic protection against bumps or scratches. Single-face corrugated boxes are lightweight and cost-effective, making them a great option for internal packaging or light-duty shipping.
Single-Wall: The most common type, featuring two liners and one fluted layer. These boxes are typically used for general shipping and storage, offering a balance of strength and cost-effectiveness. Single-wall boxes are perfect for shipping products that aren’t too heavy or fragile, and they are commonly used in e-commerce and retail packaging.
Double-Wall: With three liners and two fluted layers, double-wall boxes are designed for heavier or more fragile items. They provide enhanced strength and can handle more pressure during transit. Double-wall boxes are often used for shipping large or bulky products, as they offer better protection and durability, especially for items that are vulnerable to crushing or impact damage.
Triple-Wall: Composed of four liners and three fluted layers, triple-wall boxes are the strongest option. They are ideal for industrial-strength needs, where maximum protection is required for heavy and high-value products. These boxes are commonly used for shipping large machinery, industrial parts, and other high-value or heavy-duty items that need strong protection.

2. By Flute Profiles

Flute profiles determine the box’s ability to cushion items and resist impacts. Different flute profiles offer various levels of strength, cushioning, and printability:

A-Flute: The thickest flute profile, measuring 5mm. It is ideal for cushioning delicate items and provides excellent stacking strength. A-flute is often used for packaging fragile goods that require extra padding and protection during transit, such as glassware or ceramics.
B-Flute: At 3.2mm, this flute is puncture-resistant and commonly used for die-cut designs, providing a strong yet lightweight option for packaging. B-flute boxes are commonly found in packaging for food, cosmetics, and retail displays where a balance between strength and appearance is important.
C-Flute: Measuring 4mm, this is the most versatile and commonly used flute profile, making up 80% of corrugated boxes. It offers a balance of strength and cushioning for a variety of products. C-flute is popular for packaging heavier items, as it provides adequate protection while maintaining a cost-effective price point.
E-Flute: At just 1.5mm, this thinner flute is best for lightweight items and offers high-quality printing surfaces, making it a popular choice for retail packaging. E-flute boxes are commonly used for packaging electronics, apparel, and promotional products, where a premium look and feel are required.
F-Flute: The thinnest flute at 1mm, used for premium packaging where appearance matters. It is perfect for lightweight products that still require a premium presentation. F-flute is often used for luxury packaging, such as cosmetics, high-end electronics, or boutique products.

3. By Design Styles

The design style of a corrugated box determines how it is sealed, loaded, and used in various industries. These styles provide different levels of protection and ease of use:

Regular Slotted Container (RSC): The most commonly used design, with equal flaps that are folded in to seal the box. RSC boxes are ideal for a wide range of shipping needs, from small parcels to large bulk shipments. Their simplicity and versatility make them the go-to choice for businesses across various industries.
Half-Slotted Container (HSC): This box has an open top, making it easy to load products. It’s often used for bulkier or heavier items that don’t need a top closure. HSC boxes are also commonly used in the food industry and for packing larger, bulkier items like furniture or machinery components.
Full Overlap Slotted Container (FOL): With overlapping flaps, these boxes offer extra strength and protection, especially for heavier products or items that require more cushioning. FOL boxes are often used for shipping fragile items, such as electronics, where added security is needed to prevent damage during transit.
Telescope Boxes: A two-piece design where the lid and base fit together, providing extra space and protection. These boxes are typically used for heavy or fragile items that need added security during shipping. Telescope boxes are ideal for shipping large, irregularly shaped products, such as artwork or delicate machinery, where extra room for cushioning is needed.

These different types of corrugated boxes are designed to meet various needs, from simple shipping to specialized packaging for fragile or heavy-duty items. Now, let’s look at how their strength is tested to guarantee maximum protection during transit.

Testing the Strength of Corrugated Boxes

Before corrugated boxes are used in shipping, they must undergo rigorous testing to ensure they meet the necessary strength and durability standards. These tests help verify that the boxes can withstand the pressures of storage, handling, and transportation, ensuring that the products inside remain safe. Let's have a look at those:

Bursting Strength Test (BCT): This test measures the box's ability to withstand pressure from all sides. It simulates the pressure a box might experience when stacked with other boxes. A higher bursting strength indicates better resistance to crushing and damage.
Edge Crush Test (ECT): The ECT evaluates the box's resistance to compression along the edges. This test simulates the weight and force that the box will experience when stacked during shipping. A higher ECT score signifies stronger edge protection.
Box Compression Test (BCT): This test measures the overall strength of a box by applying pressure evenly across its surface. It helps determine how much weight a box can handle without collapsing, ensuring that it can protect heavier products during transit.
Compression Resistance: This test checks the box's ability to maintain its shape when subjected to weight or pressure. It helps to assess the overall durability of the box during storage and transport.
Drop Test: In this test, boxes are dropped from various heights to simulate the impact they may encounter during transit. The goal is to determine how well the box holds up to impacts without breaking or losing its integrity.

These strength tests are critical for businesses to ensure they’re using the right packaging to protect their products. By conducting these tests, manufacturers can confidently choose the most suitable corrugated box for their specific needs, minimizing the risk of damage during transportation.

Now that we've explored the rigorous testing process for corrugated boxes, it’s essential to understand the standards and regulations that govern their manufacturing. These guidelines ensure that boxes not only provide the necessary protection but also comply with safety, environmental, and quality requirements.

What Are the Key Standards and Regulations for Corrugated Boxes?

Corrugated boxes are subject to a range of standards and regulations designed to ensure their safety, quality, and performance. These standards come from both government bodies and industry organizations. Here’s an overview of the key regulations:

1. Box Maker’s Certification

A Box Maker's Certificate is a stamp or print on the box that indicates its compliance with specific standards. This certificate provides essential details, including the manufacturer's information, the box's specifications, and its adherence to regulations. Most importantly, it highlights the box's load-bearing capacity, which directly impacts the protection it provides.

Purpose:The Box Maker's Certificate acts as a guarantee of the box's quality and performance, ensuring it meets the necessary strength and safety standards to safeguard products.

2. Indian Standards (IS) for Packaging

The Bureau of Indian Standards (BIS) sets the regulations for packaging materials in India. These standards ensure that corrugated boxes meet the required durability, strength, and environmental standards for various industries.

Key Indian Standards for Packaging:

IS 1704: 1986 – This standard covers the specifications for corrugated fiberboard boxes used in packaging.
IS 2809: 2001 – This standard provides guidelines for the construction of corrugated boxes.
IS 15597: 2005 – It details the specifications for packaging materials, including corrugated fiberboard, used in the transport of goods.

These standards help ensure that corrugated boxes are manufactured to provide the required protection for goods while complying with national packaging regulations.

3. Indian Ministry of Environment and Forests (MoEF) Regulations

In India, corrugated boxes are also subject to environmental regulations under the Ministry of Environment, Forests and Climate Change (MoEF), which oversees the environmental impact of packaging materials.

Key Regulations:

Plastic Waste Management Rules (PWM), 2022 – While primarily focused on plastic packaging, these rules influence packaging sustainability practices, encouraging businesses to adopt eco-friendly materials such as recyclable corrugated boxes.
E-Waste Management Rules, 2016 – Ensures that packaging, including corrugated boxes, is appropriately disposed of or recycled to minimize environmental impact, particularly in industries like electronics.

4. The Joint Commission (TJC)

The TJC also impacts the medical packaging industry in India. It oversees guidelines that ensure corrugated boxes used for transporting medical supplies comply with safety and hygiene standards.

Key Guidelines Include:

AAMI ST 79 5.2.1 – Ensures medical supplies are packed in a way that they remain sterile and protected during transit.
Sterilization Packaging Guidelines – For packaging used in the healthcare industry, emphasizing cleanliness and proper handling.

5. Global Recycled Standard (GRS)

The Global Recycled Standard (GRS) is a voluntary international certification system that is relevant in India as well. It ensures that recycled materials used in corrugated boxes meet environmental and chemical safety standards.

Key GRS Features:

Verifies the recycled content of products and promotes eco-friendly manufacturing.
Helps businesses in India comply with international standards for sustainability in packaging.

These standards and regulations ensure that corrugated boxes used in India meet both local and international safety, environmental, and quality requirements. Businesses must adhere to these guidelines to ensure they are using safe, reliable, and eco-friendly packaging solutions that protect their products and the environment.

Why Choose SB Infotech for Your Packaging Solutions

SB Infotech is your trusted partner in optimizing packaging processes, especially in the corrugation and packaging sectors. With our deep expertise in providing customised ERP solutions, SB Infotech stands out by offering CorrEx, a comprehensive add-on solution for Dynamics Business Central, specifically designed for corrugation manufacturing companies. It effectively addresses the full spectrum of operational requirements, ensuring seamless integration and efficient management of all processes within corrugation manufacturing. Here's why SB Infotech is the right choice for enhancing your packaging operations:

Customised ERP Solutions: As a Microsoft Partner, SB Infotech specializes in customizing ERP solutions that streamline the corrugation manufacturing process. CorrEx offers features like FG Specification and Product Technical Specifications to capture technical details like Bursting Strength (BS), Box Compression Test (BCT), and flute types, ensuring a smooth and efficient production flow.
End-to-End Integration: CorrEx integrates seamlessly with existing business systems, allowing for real-time data exchange across production, logistics, and packaging. Features like Gate Inward/Outward and Dispatch Scheduling ensure seamless coordination and real-time tracking of materials.
Optimized Inventory Management: With Reel Management, SB Infotech’s solution helps businesses track materials, reduce waste, and maintain optimal inventory levels. The integration of barcode and QR code technology ensures accurate tracking and efficient stock management. This reduces errors, enhances real-time visibility, and ensures that businesses can keep tight control over their inventory, all while driving efficiency and cost control.
Quality Control: CorrEx includes multiple stages of quality control through Quality Checklists and Quality Inspection Sheets, ensuring that every stage of the production process meets high standards.
Subcontracting and Process Automation: The Corrugation Subcontracting Module simplifies managing outsourced tasks, and the Process Routing feature reduces human error by standardizing job templates for consistent, accurate task execution.
Machine Integration: Automating the communication between ERP systems and production machines, CorrEx enhances machine performance tracking, reducing downtime and increasing operational efficiency.
Advanced Analytics for Better Decision-Making: With tools like Power BI integration, SB Infotech allows businesses to access real-time insights into packaging and production performance, enabling smarter decision-making.

SB Infotech is committed to continuous improvement, ensuring that CorrEx grows with the changing needs of businesses. With these customised solutions, SB Infotech helps you optimize your packaging operations, improve inventory control, and ensure customer satisfaction every time.

Conclusion

Corrugated boxes are more than just a packaging solution; they play a vital role in ensuring your products reach customers safely and efficiently. Their strength, cost-effectiveness, and eco-friendly nature make them a top choice for businesses across various industries. With SB Infotech’s CorrEx solution, you can manage your packaging and shipping processes, improving inventory management, reducing waste, and ensuring timely deliveries. By choosing SB Infotech, you're investing in a customized, reliable solution that will help your business operate smoothly and stay competitive.

Contact us today to see how SB Infotech’s expertise and CorrEx can enhance your packaging operations and help you deliver a better experience to your customers.