Composition of Corrugated Cardboard
- Single Face: Consists of one flat paper sheet laminated with one corrugated sheet. It is commonly used for product cushioning or mounting onto offset-printed boxes.
- Single Wall: Made up of two flat paper sheets with one corrugated sheet sandwiched between them. The corrugated layer is placed in the middle, providing moderate strength and making it suitable for medium-weight products or items that do not require extremely high durability.
Corrugated Cardboard Thickness
The thickness of corrugated cardboard refers to the type of fluting, commonly categorized as 3-ply or 5-ply cardboard. 5-Ply Cardboard: Often produced using BC flute, which is widely used for corrugated box manufacturing. 3-Ply Cardboard: Typically made with A, B, C, or E flutes, depending on the required strength. The choice of flute type directly impacts a box’s load-bearing capacity, product protection, stacking ability, and weight, all of which affect shipping costs. Online sellers can optimize their packaging by providing key product details such as weight, fragility, and required load support, ensuring the most suitable flute type is selected for their needs.
Three Main Types of Corrugated Cardboard Boxes
Corrugated cardboard boxes need to be strong enough to support the weight of packages and products. Their strength is classified based on the number of layers, which can be divided into three main types:
- Single Face (2-Ply Corrugated Box) This type consists of two flat sheets of corrugated paper laminated together. It is commonly used for lightweight and small-sized packages. Single-face corrugated boxes are the most popular and cost-effective option.
- Single Wall (3-Ply Corrugated Box) Composed of three layers: two flat sheets with a corrugated layer in between, this structure enhances weight support and impact resistance. It is ideal for medium-sized products and parcels that require better protection than a 2-ply box.
- Double Wall (5-Ply Corrugated Box) This type consists of five layers: three flat sheets and two corrugated sheets sandwiched between them. The two corrugated layers can be adjusted in flute size based on specific needs—whether for higher weight capacity or improved impact and puncture resistance. Different flute combinations offer varying levels of protection and durability, making this box ideal for heavy or high-value products.
Grades of Corrugated Paper Used in Packaging
Corrugated paper comes in various grades, each with unique characteristics suited for different packaging needs. Let’s take a look at the different types:
KT – Brown Kraft Paper for Box Surfaces Made from 100% recycled pulp, supporting environmental conservation while maintaining durability and aesthetic appeal. Ideal for export packaging, commonly used by international brands due to its strength. Standard weight: 125, 150, 175, 205 gsm.
KI – Light Brown Kraft Paper for Box Surfaces Features a soft, light brown color that enhances printed text and images, second only to KS paper in print quality. Suitable for products that do not require high strength, such as ready-to-eat food boxes and printed electrical appliance packaging. Standard weight: 125, 150, 185 gsm.
KA – Golden Yellow Kraft Paper for Box Surfaces Highly durable and excellent for heavy-duty packaging. Popular in automotive parts, canned food, and furniture boxes that require stacking strength and impact resistance. Standard weight: 125, 150, 185, 230 gsm.
KS – White Kraft Paper for Box Surfaces Smooth and clean, ideal for high-quality printing and premium product packaging. Strong and protective, commonly used for electronic goods, export packaging, and high-end consumer products. Standard weight: 170 gsm.
KK – Brown Kraft Paper for Box Surfaces (Recycled) Made from 100% recycled pulp, offering sustainability while maintaining strength and stackability. Preferred for export products that require fully recycled material. Standard weight: 125, 150, 185 gsm.
CA – Brown Kraft Paper for Corrugated Flutes Produced from 100% recycled pulp, making it environmentally friendly. Used mainly for corrugated flutes in all types of cardboard boxes or as liner board. Offers high stacking strength and impact resistance. Sometimes used as a back liner to reduce costs. Standard weight: 85, 100, 105, 115, 125, 150, 185 gsm.
Corrugated Paper Packaging: 3-Layer vs. 5-Layer Boxes
When selecting packaging for your products, it is important to choose between 3-layer and 5-layer corrugated boxes based on their weight capacity, strength, and intended use. While both are made from corrugated paper, they have different properties and levels of durability. Additionally, these boxes are eco-friendly and biodegradable. Below are the differences and suitable applications for each type:
3-Layer Corrugated Paper Packaging
- Weight Capacity: Should not exceed 6 – 10 kg (evenly distributed).
- Not Suitable For: Liquid products.
- Best for: Various lightweight items such as kitchenware, clothing, and miscellaneous household goods.
- Packing Considerations: Ensure the box is properly sealed to prevent damage during transportation.
- Not Suitable For: Hazardous materials.
- Inspection Tip: Check the box for any damages, such as tears or pest infestations, before use.
5-Layer Corrugated Paper Packaging
- Weight Capacity: Should not exceed 20 kg (evenly distributed).
- Not Suitable For: Liquid products.
- Best for: Heavier and bulkier items, such as fruits, plants, and electrical appliances.
- Packing Considerations: Distribute weight evenly inside the box to avoid damage.
- Not Suitable For: Live animals.
- By choosing the right type of corrugated box, you can protect your products, reduce damage, and ensure a smooth shipping process.
