Corrugated Packaging

What is corrugated cardboard packaging?

Corrugated cardboard is a recyclable and environmentally friendly packaging material. It is made from paper from either sustainable forest sources, or fully recycled paper, very much like moulded pulp. It is manufactured with rows of air columns making the paper stronger than average cardboard. The air acts as a cushion for the items inside of the packaging and the ridges inside provide strength and flexibility to prevent breakages.

Depending on the grade and finish of the board, corrugated packaging is very elegant, strong, and long lasting.


So what are the key benefits of corrugated packaging?


  • Recyclable and sustainable, made from raw materials.
  • ​Improves brand image and reduces your businesses carbon footprint.
  • ​Corrugated cardboard is both lightweight and extremely strong.
  • ​Its high-tech construction ensures the material can carry a wide range of weights, and is moisture resistant. 
  • Corrugated cardboard packaging protects. Corrugated cartons provides a stable cushion for any product, keeping items safe during long-distance transportation, shipping and handling.
  • ​It is extremely customisable. The differing grades of corrugated cardboard can be adjusted to make it a perfect fit for any product. What’s more, corrugated cardboard can receive different coatings, treatments and adhesives and it can even become flame resistant. Corrugated comes in all sizes and can be easily folded into different shapes to make it a perfect fit for any industry.
  • Corrugated cardboard is cost-effective and sustainable. Corrugated cardboard boxes are some of the least expensive cartons available. They don’t require high labour costs or costly tools to manufacture and fill the boxes. Apart from that, corrugated is easy to recycle and the boxes can be folded back up and stored away for later use.
  • Allows for different coatings, treatments and adhesives to be used across a range of sectors and it can even become flame resistant.





Corrugated packaging



Where does our process with corrugated packaging begin?


Let’s start from the beginning. Our work with corrugated packaging usually starts with an initial design consultation to understand your product, company and client requirements. We often work with clients who are looking to switch to sustainable materials or whose current corrugated designs aren't doing their products justice. With our level of experience, our expert technical and design team then works to create robust designs to overcome any breakage issues and create packaging which will make a great first impression and user-experience. We like to show you these designs using our in-house 3D CAD software so you can easily visualise your designs.

The next steps are the samples and stress tests. Once you’re happy with the design, our team then create samples and carry out rigorous stress tests – ensuring the packaging provides the utmost protection.

When the design and performance are approved, your packaging is then manufactured to your chosen quantities with quality checks carried out. Please feel free to email us or complete the form below if you are interested in corrugated, if you are unsure what material would be best suited to your product, or if you would just like some friendly chat! 


Where can corrugated cardboard packaging be used?


Take a look at our gallery below! Corrugated cardboard is the packing material of choice for many brands and industries. It is ideal for products which require a high-degree of outer packaging protection. It can have a polished or rustic appearance and has many uses such as for furniture, exhibitions, games and art. But by no means is restricted to these.

As a sustainable packaging company, we have great experience working with corrugated materials. Creating designs that are protective, user-friendly, beautiful and bespoke. One of our latest projects involved working with TOU to design and create e-commerce packaging for their luxury sandwich, you can view the full case study here.

Corrugated packaging


Different types of corrugated cardboard? 

Corrugated cardboard comes in several different thicknesses, or flute types. These are alphabetical listed as A, B, C, E, F, G and N as the most common varieties, agreed across the world. The board grade will depend on the size of the box, the weight it has to hold, and whether the product going inside is load bearing or fragile, and finally how it is going to be handled once in use, for instance, going out on pallets, stored in refrigerated conditions and for several months at a time. Each flute type has an agreed thickness profile, so B = 3mm, C = 4mm and E = 1.5mm for example.

Single wall corrugated cardboard such as B or C flute is generally used for outer boxes and cartons. E flute is mainly used for inner containers such as transit boxes, presentation boxes with fitments or smaller countertop displays. F flute is ideal for longer production run prestige jobs as it can be litho printed direct to the board, without the need for lamination of paper, saving costs.

Double wall corrugated cardboard is used where stacking strength is important, or for free standing displays. Double wall EB and EE flutes are useful for providing a good printing surface as the outside liner is always on the smaller flute profile.


Find out more

If you would like to know more about our corrugated work, or how it could work with your products, please drop us an email or fill out the form below, we would love to hear from you. 

Our team has over 30 years of experience working with corrugated materials, and there is a reason why it is so commonly used.

Please call us if you would like additional information 01580 236 128

or fill in the form below, all fields must be completed.

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