How is Cardboard Packaging Manufactured?

How is Cardboard Packaging Manufactured?

Corrugated cardboard boxes are widely used for shipping goods, but how are they manufactured and why are they a popular packaging material?

How are Cardboard Boxes Made?

Renewable materials

Corrugated cardboard is made from a high percentage (over 70%) of recycled cardboard fibres, combined with raw paper pulp from trees. The production process involves heating the fibres at high temperatures. This method is effective at killing off any micro-organisms, making the packaging safe for reuse, time and again.

Layered profile

Corrugated cardboard is formed from layers of paper. An undulating fluted layer adheres to two outer sheets of flat paper. Air is held in the fluted layer, providing insulation and cushioning for the products inside.

For particularly weighty or delicate goods, double-walled corrugated cardboard is available. This has an additional layer of fluting and a flat sheet. Although it’s only made up of 5 sheets of paper, it is incredibly robust.

Creating boxes

Corrugated cardboard sheet is used as a packaging material, but it is usually formed into boxes. This requires a template to be prepared to the desired dimensions. Die cut areas and folds are included in this template, which is fitted to the machine.

Cardboard sheets are fed into machines to create cuts and folds in the desired location. Modern machines can be set up to minimise offcuts and also add flexographic print, whilst manufacturing at speed.

Cardboard boxes are usually supplied flat packed to minimise the storage space required. Just assemble and pack as required!

Are There Standard Cardboard Box Sizes?

The packaging industry has a variety of standard box shapes and sizes, known as the FEFCO Code. This helps to standardise production and saves lots of time trying to describe packaging designs and specifications. There are over 100 standard styles which include variations of:

• Slotted Boxes
• Telescopic Boxes
• Tray Boxes
• Sliding Boxes
• Rigid Boxes

They are used as industrial cartons, e-commerce packaging, luxury gift packs and takeaway food boxes, to name but a few.

Packaging suppliers offer a range of standard stock boxes, ready for off-the-shelf purchasing. If you want something different, speak to a packaging manufacturer like us. We produce custom dimensions, design concepts and details. This may sound expensive, but we provide cost-effective bespoke packaging solutions.

Why are Cardboard Boxes so Widely Used?

As a manufacturer or retailer, you want a durable packaging material to reliably protect goods in transit. Lightweight packaging is ideal as it doesn’t significantly increase shipping costs. For supply chain sustainability, you want the packaging to be made from a renewable source. Corrugated cardboard packaging ticks all these boxes and more!

Cardboard packaging can be reused and is widely recycled, lowering your environmental impact. In addition, it’s straightforward to print cardboard to achieve branded packaging and, it is a low-cost packaging material. What’s not to like?

Where can I get Packaging Advice?

If you have launched, or are growing, an e-commerce business, packaging supplies are essential, however, this is unlikely to be your area of expertise. Fortunately, it is ours and we can help.

Get in touch and tell us about your product and how it will be shipped and stored. Share your design ideas and eco priorities with us. We can then advise on packaging options, including print finishes, that fit your specification.

We are happy to send a quote and a sample box to help you make an informed decision. Our packaging advice has helped many businesses to get what they want at the best price. How can we help you?

Give us a call on 01296 436888 or email enquiries@abcbox.co.uk.