For the song by Flo, see Cardboard Box (song)
Corrugated shipping container, one type of cardboard boxCardboard boxes are industrially prefabricated boxes, primarily used for packaging goods and materials. Specialists in industry seldom use the term cardboard because it does not denote a specific material.[1][2] The term cardboard may refer to a variety of heavy paper-like materials, including card stock, corrugated fiberboard,[3] and paperboard.[4] Cardboard boxes can be readily recycled.
Terminology
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Several types of containers are sometimes called cardboard boxes:
In business and industry, material producers, container manufacturers,[5] packaging engineers,[6] and standards organizations,[7] try to use more specific terminology. There is still not complete and uniform usage. Often the term "cardboard" is avoided because it does not define any particular material.
Broad divisions of paper-based packaging materials are:
There are also multiple names for containers:
History
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The first commercial paperboard (not corrugated) box is sometimes credited to the firm M. Treverton & Son[9] in England in 1817.[10][11][12] Cardboard box packaging was made the same year in Germany.[13]
The Scottish-born Robert Gair invented the pre-cut cardboard or paperboard box in 1890 – flat pieces manufactured in bulk that folded into boxes. Gair's invention came about as a result of an accident: he was a Brooklyn printer and paper-bag maker during the 1870s, and one day, while he was printing an order of seed bags, a metal ruler normally used to crease bags shifted in position and cut them. Gair discovered that by cutting and creasing in one operation he could make prefabricated paperboard boxes. Applying this idea to corrugated boxboard was a straightforward development when the material became available around the turn of the twentieth century.[14]
Cardboard boxes were developed in France about 1840 for transporting the Bombyx mori moth and its eggs by silk manufacturers, and for more than a century the manufacture of cardboard boxes was a major industry in the Valréas area.[15][16]
The advent of lightweight flaked cereals increased the use of cardboard boxes. The first to use cardboard boxes as cereal cartons was the Kellogg Company.
Corrugated (also called pleated) paper was patented in England in 1856, and used as a liner for tall hats, but corrugated boxboard was not patented and used as a shipping material until 20 December 1871. The patent was issued to Albert Jones of New York City for single-sided (single-face) corrugated board.[17] Jones used the corrugated board for wrapping bottles and glass lantern chimneys. The first machine for producing large quantities of corrugated board was built in 1874 by G. Smyth, and in the same year Oliver Long improved upon Jones's design by inventing corrugated board with liner sheets on both sides.[18] This was corrugated cardboard as we know it today.
The first corrugated cardboard box manufactured in the US was in 1895.[19] By the early 1900s, wooden crates and boxes were being replaced by corrugated paper shipping cartons.
By 1908, the terms "corrugated paper-board" and "corrugated cardboard" were both in use in the paper trade.[20]
Crafts and entertainment
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Cardboard and other paper-based materials (paperboard, corrugated fiberboard, etc.) can have a post-primary life as a cheap material for the construction of a range of projects, among them being science experiments, children's toys, costumes, or insulative lining. Some children enjoy playing inside boxes.
A common cliché is that, if presented with a large and expensive new toy, a child will quickly become bored with the toy and play with the box instead. Although this is usually said somewhat jokingly, children certainly enjoy playing with boxes, using their imagination to portray the box as an infinite variety of objects. One example of this in popular culture is from the comic strip Calvin and Hobbes, whose protagonist, Calvin, often imagined a cardboard box as a "transmogrifier", a "duplicator", or a time machine.
So prevalent is the cardboard box's reputation as a plaything that in 2005 a cardboard box was added to the National Toy Hall of Fame in the US,[21] one of very few non-brand-specific toys to be honoured with inclusion. As a result, a toy "house" (actually a log cabin) made from a large cardboard box was added to the Hall, housed at the Strong National Museum of Play in Rochester, New York.
The Metal Gear series of stealth video games has a running gag involving a cardboard box as an in-game item, which can be used by the player to try to sneak through places without getting caught by enemy sentries.
Housing and furniture
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Living in a cardboard box is stereotypically associated with homelessness.[22] However, in 2005, Melbourne architect Peter Ryan designed a house composed largely of cardboard.[23] More common are small seatings or little tables made from corrugated cardboard. Merchandise displays made of cardboard are often found in self-service shops.
Cushioning by crushing
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Mass and viscosity of the enclosed air help together with the limited stiffness of boxes to absorb the energy of oncoming objects. In 2012, British stuntman Gary Connery safely landed via wingsuit without deploying his parachute, landing on a 3.6-metre (12 ft) high crushable "runway" (landing zone) built with thousands of cardboard boxes.[24]
See also
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References
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Although most people confuse corrugated boxes with cardboard boxes, they are not the same. This might lead to a misunderstanding of the terminology. Cardboard is a heavy-duty paper stock that is widely used to make folding cartons and other items.
Folding carton boxes covering supermarket aisles are frequently made of cardboard. Consider a cereal box or a package of mac & cheese. This is hardly the kind of package you'd expect to make it through the shipping procedure. If you send one of these in the mail, it will almost certainly arrive in tatters.
The strength of a corrugated box, on the other hand, is paramount.
A liner and a medium make up corrugated boxes. These paper sheets are bonded together. They're usually three layers of fiberboard, but they might be substantially thicker.
The linerboard, or simply the liner, is the outer layer. Liners are flat materials that are normally found on the outside of the board, but can sometimes be found on the interior, as in the case of a double or triple wall.
The flute, which is a wavy layer in the center, is the medium. Corrugated packing boxes' strength comes from this inner player, which is why they're so popular for transport and storage.
Kraft and test paper are the two most common types of paper used in corrugated boxes. The interior liner of the box is usually made of test paper, while the exterior liner is made of kraft paper.
Kraft paper is pricier than test paper, but it is of superior quality. Kraft paper is created from 70-80% virgin chemical pulp fiber and is made from softwood trees such as Pine, Spruce, and Fir. It's available in a variety of colors and textures, including brown, white, speckled, totally bleached, and birch-faced.
Kraft paper also has a smoother texture, making it easier to print on. It's also more water-resistant, which means the contents are better protected. It's also more durable than test paper due to its increased rip and burst resistance.
The Flute is C-Shaped curls in between to the two substrates, also called "corrugation". It is used to strengthen or reinforce the walls of your packaging. They look like wavy c-shaped lines that are glued to a paperboard. Fluting in the box gives your packaging strength and helps withstand any damage.
The flute size influences the thickness of the box walls and the stacking strength of the box. Flutes are identified by a letter that indicates their size. They're counted by their thickness and the number of flutes per linear foot.
The most popular flute sizes are:
At 1/4" thick, the A-Flute (33 flutes per linear foot) is the biggest flute. Because of its thickness, it provides a lot of protection and is a fantastic choice for fragile things.
B-Flute is 1/8" thick and has 47 flutes per linear foot. This is much thinner than A-flutes, but it has a surprising amount of strength. It’s often used for counter displays or canned goods. Die-cut designs are common with this flute.
3/16" thick C-Flute (39 flutes per linear foot). Because it's the most popular option for shipping boxes, this is definitely the one you're most familiar with.
E-Flute (90 flutes per linear foot) is extremely thin, measuring only 1/16" thick. It lacks the strength of the larger flutes, although it does have some benefits. For folding carton boxes, it's occasionally used instead of paperboard. It's easy to store and use, and it prints well.
F-Flute (125 flutes per linear foot) is the narrowest of the flute classes at 1/32" thick. Because of its smooth surface, printed designs will appear sharp.
Even if you already know what flute size you want, you'll need to make some essential choices.
Corrugated packaging is available with a variety of wall thicknesses. Sometimes you just need a little extra protection for your items, and other times you need something more substantial.
Here are the are few types of walls you can choose from:
This is a single sheet of liner attached to one sheet of corrugated media that is normally offered in rolls. It provides extra padding for fragile things. If you're transporting something fragile like glass or electronics, you might use this as an extra layer of protection.
One sheet of corrugated medium is attached between two sheets of liner in a single-wall construction. It's the most prevalent and what most people think of when they think of a corrugated cardboard box.
This is more durable than single-wall, although it is less flexible due to the additional layer. This is sometimes used in certain POP Displays and packaging when additional protection or strength is needed. But it can potentially cause issues when printing, so the artwork must be designed to work specifically with its unique structure.
With three stacked corrugated sheets and four liner board facings, this is the strongest. It's commonly utilized for industrial parts or produce containers. It's extremely heavy-duty, and can be difficult to print certain artwork, just like double-wall. So if you choose triple-wall, it must be for a certain application.
Finding the perfect fit is also vital when choosing the right corrugated packing box for your products. Corrugated boxes are available in a variety of forms and sizes. You don't want to squeeze your belongings, but you also don't want them to float around. There are more packaging options, but these learning about the different styles is important.
Keep in mind that the internal dimensions of a box are stated as length x width x height when choosing a box size (L x W x H).
Here are some of the most popular box styles to pick from:
The most common is this one. Consider a standard shipment box. All of the flaps on this box are the same length, and when the box is closed, the two outer length flaps meet in the middle. The flaps will need to be taped together.
Because both sets of outside flaps fully overlap, making the box double-layered on top and bottom, this sort of box has increased strength.
You've probably seen one of these boxes if you've ever ordered a book or other media materials online. They're folded into a box after being creased and slotted. They're sleek but functional.
This box has a top and bottom that fit over each other, as the name implies. Its increased strength comes from the twin walls. Of course, these containers must be sealed in some way. For heavy-duty loads, corrugated boxes are usually sealed with packaging tape, tuck-in flaps, or strapping.
All of these options can be intimidating, but there are a variety of tools and services to help you get started on your search for the ideal box. If you'd like to learn more, you can talk to a representative at Bennett Packaging.
Of course, if you've gone to the work of figuring out what flute grade and wall type you'll need, you'll want some confidence that the box will perform as expected. And, in the end, that means safeguarding the contents of the box.
Everyone wants a box that will keep their belongings safe. No one wants to find their packaging crumpled and the items inside damaged.
Corrugated boxes go through a thorough testing process when it is needed. Depending on the retailer, or situation you are in, you might need to go through one yourself.
Here are four of the main tests conducted for corrugated boxes:
The Edge Crush Test determines the box's stacking strength, which can help you determine things like pallet shipment durability. ECT is a laboratory test procedure that involves compressing the board's edge between two plates. It's expressed in pounds per linear inch and is used to calculate a box's maximum compression force.
The force required to rupture or puncture corrugated cardboard is measured in the Bursting Test. This test determines how well a box will protect the contents of the box during shipping.
The Flat Crush Test assesses corrugated paperboard's resistance to flute crushing. Whether you pick digital or offset printing, this will help you calculate how much pressure you can safely apply to your box throughout the printing process.
Under defined settings, a Water Absorption Test determines how much water corrugated fiberboard absorbs over a period of time.
Finding the right corrugated box for your needs can be a daunting task. However, with the help of this guide, you should now have a better understanding of what to look for when ordering custom packaging. Finding a packaging manufacturer is an important step in your business, and we are here to help.
Always keep in mind the importance of protecting your belongings during transit, and remember that Bennett Packaging is here to help with all of your corrugated box needs. Contact us today for a custom quote on boxes.