Corrugated Box Manufacturers and Suppliers

Corrugated Boxes

Corrugated boxes are storage and shipping containers made from corrugated materials, which typically consist of a type of paperboard that has been fluted, rippled, or ridged for added strength and durability. These containers are most commonly constructed from corrugated fiberboard, a material that features a wavy, corrugated sheet positioned between two flat liner sheets. This layered design enhances structural integrity, making the boxes lightweight yet highly durable. Although the term "cardboard box" is frequently used to describe these containers, it is technically inaccurate, as true cardboard lacks the reinforced structure that defines corrugated packaging.

The History of Corrugated Boxes

Throughout history, packaging materials have consistently been chosen based on cost-effectiveness, favoring the least expensive options available. As a result, paper and its derivatives were largely absent from packaging applications for most of human history. It was only in the mid-1800s, with the development of industrial pulping processes, that paper became widely used for packaging.

The first recorded use of corrugated paper dates back to 1856, when it was patented in England for use as a hat liner. However, it was not until 15 years later, in 1871, that Albert Jones of New York City patented single-faced corrugated board for shipping purposes. Jones’s design laid the groundwork for modern corrugated materials, and in 1874, Oliver Long expanded upon it by adding a second liner sheet, creating the foundational structure of corrugated fiberboard as it exists today. That same year, G. Smyth introduced the first large-scale corrugating machine, enabling mass production of corrugated materials.

The corrugated packaging boxes familiar today—both in terms of material and structural design—emerged toward the end of the 19th century. In 1884, Swedish chemist Carl F. Dahl pioneered the development of kraft paper, a strong, tear-resistant material derived from pulverized wood chips. By 1906, kraft paper was being produced on a large scale, forming the basis for stronger, more durable packaging solutions. Interestingly, the discovery of corrugated shipping boxes was largely accidental. In 1890, Brooklyn-based printer Robert Gair stumbled upon the key technique when a malfunctioning creasing tool on a paper seed bag production line unexpectedly performed cutting actions instead. Initially, corrugated boxes were used mainly for packaging fragile items such as glass and pottery, but their applications soon expanded to include farm produce and a variety of other goods.

By the turn of the millennium, paper-based packaging had transformed from a last-resort option into a dominant force in the industry. In 1992, corrugated fiberboard production in the United States surpassed 25 million tons, a testament to its widespread adoption and growing importance in global packaging and logistics.

Differences Between Paper Products

Although the terms cardboard, paperboard, and corrugated material are often used interchangeably, they have distinct technical differences. The broad term cardboard can refer to any heavy material derived from paper pulp, but it is generally avoided in the packaging industry due to its imprecision. Similarly, paperboard describes a heavy paper-based material that differs from standard sheet paper primarily in its greater thickness.

Chipboard is a more specific term, referring to a product made from recycled paper that is pressed to a designated thickness. Lightweight packaging, such as boxes for board games or cereal, is typically made from chipboard. Based on the earlier definitions, these boxes could also be categorized as cardboard or paperboard boxes, though chipboard remains the most accurate designation.

Corrugated fiberboard is the correct technical term for the most commonly used material in corrugated boxes. This material consists of three layers of kraft paper (a specialized type of paperboard or cardboard), with a corrugated (rippled) interior layer sandwiched between two flat liners. Although some sources mistakenly define corrugated material as any three-layered construction, the term "corrugated" specifically refers to the presence of flutes—the rippled or pleated structure within the middle layer. These flutes serve a crucial role by trapping air, which enhances cushioning and significantly improves the durability of corrugated products. While many three-layered materials exist, corrugated fiberboard is distinct due to this structural reinforcement.

Despite these technical distinctions, the packaging industry sometimes uses colloquial terms like "corrugated cardboard" to simplify communication and prevent confusion among consumers. Additionally, different industries may label these materials differently based on their specific applications. However, for consumers, understanding these differences is important, particularly for making informed purchasing and recycling decisions.

Advantages of Corrugated Fiberboard

Some advantages of corrugated fiberboard include:

Corrugated Boxes Cost

 One of the greatest advantages of corrugated boxes is their affordability. Thanks to advancements in industrial technology, paper-based packaging has evolved from a secondary choice into one of the most highly valued options in the industry. The production, filling, and shipping costs for corrugated containers are low, and the materials used to manufacture them remain inexpensive, making them an economical solution for businesses.

Easy Handling of Boxes

Corrugated boxes are widely preferred in the packaging industry due to their lightweight nature. Their low weight makes them easy to handle, transport, and store, significantly reducing shipping costs and simplifying logistics for businesses.

Reliability for Shipping Products

Despite being made from kraft paper, the fluting structure of corrugated boxes provides exceptional strength and cushioning, ensuring that products inside are well-protected. This built-in shock absorption minimizes damage from weather-related conditions or travel-related shipping hazards, making them a trusted choice for packaging fragile or valuable goods.

Durability of Boxes

 Corrugated boxes are designed to be long-lasting. As long as they are kept dry and free from excessive moisture exposure, they can be reused multiple times, making them a durable packaging solution for both businesses and consumers.

Versatility of Corrugated Boxes

 The adaptability of corrugated boxes contributes significantly to their widespread use. These boxes can be customized in terms of shape, size, color, and structure, making them suitable for industries with unique packaging requirements. Beyond their initial use, corrugated boxes are highly reusable—what starts as packaging for a microwave can later serve as a moving box, storage container, or even repurposed for creative DIY projects.

Compatibility With Graphic Design

 The flat linerboard layers on the exterior of corrugated fiberboard provide an ideal surface for branding, marketing text, and custom graphics. Unlike more expensive or less printable materials, corrugated boxes allow businesses to showcase logos, product information, and promotional designs directly on the packaging, enhancing visibility and customer engagement.

Boxes are Recyclable

 Corrugated boxes are one of the most sustainable packaging options available today. Over 70% of corrugated materials are recovered, recycled, and repurposed into new corrugated boxes and other paper-based products. In 2006 alone, 25.2 million tons of corrugated material were recycled, reinforcing their role in environmentally responsible packaging. This high recyclability makes corrugated boxes an appealing choice for industries looking to reduce their environmental impact and support sustainable business practices.

Disadvantages of Corrugated Boxes

Limitations on Range of Packaged Products

One of the primary drawbacks of corrugated boxes is their lightweight construction. While this feature is advantageous for shipping and handling, it also means that corrugated containers may not be suitable for transporting heavier products. Items with significant weight or structural demands often require sturdier alternatives, such as plastic, metal, or reinforced wooden containers, to prevent damage or failure during transport.

Sanitary Concerns

 The porous nature of corrugated fiberboard can present hygiene challenges in certain industries. In environments such as hospital food storage and medical supply distribution, concerns over contamination arise due to the material's tendency to absorb liquids, harbor bacteria, and attract insects. As a result, some businesses in these sectors are actively working to minimize their reliance on corrugated containers, opting instead for non-porous packaging solutions that provide better resistance to moisture and microbial exposure.

Production Process of Corrugated Boxes

As previously mentioned, corrugated boxes are primarily made from a high-quality paperboard known as kraft paper. While corrugated boxes are typically constructed from paper-based materials, they can also be manufactured from other materials when additional strength or durability is required. Corrugated plastic containers serve as a common alternative, particularly for applications demanding greater structural integrity.

Kraft paper is produced using recycled paper, sawdust, and wood chips, which undergo a sophisticated bonding process involving heat, pressure, and adhesives to create heavy-duty paper. Although kraft paper serves as the foundation of corrugated boxes, its production is typically separate from the corrugation process. Paper mills focus on manufacturing kraft paper, while corrugating plants transform it into corrugated fiberboard, an arrangement driven by economic efficiency.

At its core, the foundation of corrugated boxes is the pine tree. Some of the largest manufacturers own thousands of acres of pine forests, along with paper mills dedicated to processing harvested, branchless trunks. At these mills, pine trunks are stripped of their bark and reduced to small wood chips before undergoing the kraft (or sulfate) process. During this process, the wood chips are "cooked" in a highly alkaline sodium hydroxide (NaOH)-based solution, breaking them down into a fibrous pulp. This pulp is then refined and processed using a specialized paper-making machine called a Fourdrinier machine, which forms it into sheets of kraft paper through an extensive dehydration process.

Corrugated box manufacturers maintain large inventories of kraft paper reels received from paper mills. To convert this paper into corrugated fiberboard, they employ massive machines known as corrugators, which can be as long as a football field. The kraft paper is first humidified at high pressures using preheating rollers, softening it for the corrugation process. Next, it passes through corrugated molds, which press ripples or flutes into the material, forming the essential structure of corrugated fiberboard.

The first gluing stage, called the single-facer glue station, bonds the first flat liner to the newly corrugated material. The double-backer glue station then attaches the second flat liner to the opposite side, completing the corrugated fiberboard sheet. The fluted paper is secured to both liner layers using a corn starch-based adhesive, which forms strong, permanent bonds. The newly assembled corrugated fiberboard is then dried over steamy hot plates and often sanded for smoothness or coated with a glossy, waterproof finish for added durability.

At the end of the corrugator, the continuous sheet of fiberboard is cut into large sheets (or box blanks), preparing them for conversion into finished boxes. High-precision corrugators used in modern manufacturing facilities can produce up to 500 feet of corrugated fiberboard per minute, ensuring mass production efficiency.

Although the raw materials for corrugated fiberboard are typically processed at separate facilities, the production of finished boxes is often integrated within the same plant. Once formed, the corrugated fiberboard is fed into box-making machines, which cut, fold, and shape it into ready-to-assemble boxes or containers. Most corrugated boxes are produced in high volumes and sold in bulk, typically in bundles of 20 to 50 boxes at a time. To maximize shipping efficiency, these boxes are always sold and transported in a flattened state, reducing storage space and transportation costs.

Design of Corrugated Boxes

• Telescope-type boxes (Series 03) – Feature a movable lid for adjustable depth.
• Folder-type boxes (Series 04) – Constructed from a single folded piece, typically forming the bottom of the box rather than the sides.
• Sleeve-style boxes (Series 05) – Designed with a separate sleeve-like lid that slides into place.
• Rigid three-piece boxes (Series 06) – Require stitching and gluing for structural assembly.

Flute Types in Corrugated Boxes

Corrugated box materials can be highly customized to meet specific functional requirements. Factors such as the type of material used, the flute size, and the binding adhesive applied during the corrugation process all influence the box’s final properties.

Among these factors, flute types play a crucial role in determining the performance of a corrugated container. Larger flutes provide superior cushioning and shock absorption, making them ideal for fragile shipments, while smaller flutes offer greater structural integrity and a smoother surface for printing and branding. Flute sizes are classified using a lettering system (A, B, C, E, and F), which does not indicate size but rather the order in which each flute type was introduced. Each flute type differs in the number of flutes per linear foot, with C-flute being the most widely used in shipping containers, featuring approximately 39 flutes per linear foot. Compression strength, cushioning capacity, and overall board thickness are all influenced by flute size and density.

Corrugated fiberboard can also incorporate multiple flute types within a single board to optimize strength and durability. This is possible due to the customization of wall layers within the material. A single-face fiberboard consists of one liner attached to a single corrugated layer, while double-walled and triple-walled boards feature multiple layers of fluting sandwiched between outer liners, significantly enhancing durability and load-bearing capacity.

Appearance Options for Boxes

Corrugated boxes come in a variety of shapes and sizes, depending on their intended use. Some boxes are single-piece constructions, while others feature detachable lids. The most common shapes include rectangular, square, and cylindrical designs, with square and rectangular boxes being the most prevalent. Once a box is ready for application, it is assembled from corrugated fiberboard, often by folding flaps on both ends of a flat board. Many corrugated boxes are folding boxes, secured in place by their own flaps rather than using tape or fasteners.

The Regular Slotted Container (RSC) is the most widely used type of corrugated box. Classified as part of the "Series-02" family by the European Federation of Corrugated Board Manufacturers (FEFCO), RSC boxes feature uniform-length flaps extending from the score line to the edge. Other corrugated box families, as defined by FEFCO, include:

Custom boxes can be produced in specialized shapes to accommodate uniquely shaped items. Die-cutting machines, which use sharp metal blades or infrared lasers, enable manufacturers to produce a wide variety of box styles tailored to customer specifications.

Corrugated boxes are available in multiple colors and finishes. Some feature bleached or mottled exteriors, replacing the natural brown hue with a clean white finish for a polished look. Commercial product packaging—such as for cereal, soap, toothpaste, and electronics—often includes a laminated, glossy exterior printed with vibrant branding, logos, and product details. Despite these variations, the most commonly used corrugated boxes remain natural brown and white cardboard.

Specialty corrugated boxes provide custom solutions for storage, handling, and shipping needs. Manufacturers can design custom-printed corrugated boxes, corrugated boxes with dividers, wax-coated corrugated boxes, and many other tailored styles to meet industry-specific demands.

Usage of Corrugated Boxes

Corrugated fiberboard is widely used for container manufacturing because corrugation significantly enhances strength without adding excessive weight. Corrugated boxes are known for their durability and longevity, making them the preferred choice for shipping, storage, and short-term organization, such as mail delivery applications.

Consumers and businesses encounter corrugated boxes in everyday life across various industries. Many commercial products rely on corrugated packaging, including toothpaste, cereal, soap, computer paper, and check refills. Other common corrugated products include pizza boxes, retail packaging, gift boxes, jewelry containers, bakery and cake boxes, and custom display packaging.

Corrugated packaging is a critical component in numerous industries, including food processing, toys, automotive, publishing, electronics, and construction. Its ability to provide protection, customization, and sustainability makes it an essential packaging material across global markets.

Corrugated Box Types

Cardboard Bins

Cardboard containers that are typically trapezoidal or rectangular in shape and designed without a lid, often used for easy-access storage and display.

Cardboard Storage Boxes

Durable cardboard containers specifically designed for long-term storage, offering protection for documents, household items, and archived materials.

Corrugated Cartons

Corrugated containers that are often custom-designed to fit a specific product, providing structural support and cushioning during storage and transport.

Corrugated Trays

Open-top corrugated containers commonly used for display purposes or paired with shrink-wrap coverings to secure and showcase products in retail environments.

Five Panel Folder Boxes

Shipped flat without any pre-folded joints, these boxes feature five long panels, with one panel fully overlapping. The ends are also designed to fully overlap, providing enhanced protection and stability.

Full Overlap Boxes

Constructed with major flaps that fully overlap, increasing the strength and stability of the box, making it ideal for shipping heavy or fragile items.

Full Telescope Boxes

Designed with two telescoping sections that fit over one another for added protection. The sections may be secured using staples, die-cut locks, or adhesives for a secure closure.

Partial Telescope Boxes

Consist of two sections, with the top telescoping partially over the bottom, providing additional reinforcement while maintaining easy accessibility.

Standards and Specifications for Corrugated Packaging

The corrugated packaging industry commonly adheres to standards established by ASTM International, a U.S.-based organization that develops and publishes technical standards through voluntary consensus. These standards play a critical role in assessing key properties of corrugated fiberboard and its products, such as breaking strength, tear resistance, and durability.

Below are the primary ASTM standards used in the industry:

• D1974 / D1974M -16 – Standard Practice for Methods of Closing, Sealing, and Reinforcing Fiberboard Boxes
• D2658 – 04 (2013) – Standard Test Method for Determining Interior Dimensions of Fiberboard Boxes (Box Gage Method)
• D3951 – 15 – Standard Practice for Commercial Packaging
• D4727 / D4727M – 17 – Standard Specification for Corrugated and Solid Fiberboard Sheet Stock (Container Grade) and Cut Shapes
• D5118 / D5118M – 15 – Standard Practice for Fabrication of Fiberboard Shipping Boxes
• D5168 -12 (2017) – Standard Practice for Fabrication and Closure of Triple-Wall Corrugated Fiberboard Containers
• D5639 / D5639M – 11 (2015) – Standard Practice for Selection of Corrugated Fiberboard Materials and Box Construction Based on Performance Requirements
• D6804 – 02 (15) – Standard Guide for Hand Hole Design in Corrugated Boxes

​These standards ensure quality, consistency, and performance in corrugated packaging, helping manufacturers meet industry expectations for strength, durability, and usability in various applications.

Things to Consider When Purchasing Corrugated Boxes

With well over a thousand corrugated box manufacturers in the United States alone, selecting the right manufacturer for your packaging needs is a crucial decision. The ideal manufacturer will provide customized solutions, adhere to industry standards, ensure product security, and support branding efforts.

• The intended purpose of your corrugated packaging
• Preferred box design and customization options
• The manufacturing timeline
• How the boxes will be stored and transported

​The right manufacturer will offer custom-printed corrugated boxes, corrugated boxes with dividers, wax-coated corrugated boxes, and other specialized designs to fit various applications.

• If the boxes will be used internally (e.g., with pallets or machinery), order based on external dimensions.
• If the boxes are intended for shipping to end users, focus on internal dimensions to ensure a proper fit for your products.

Customized Packaging and Manufacturers

A quality manufacturer will work closely with customers to develop packaging solutions tailored to their specific needs. Key aspects to discuss with a manufacturer include:

Manufacturer’s Certification and Standards

It is important to verify whether a manufacturer follows ASTM standards for corrugated packaging. Additionally, consider whether the manufacturer holds quality management certifications, such as ISO 9001, which ensures consistent quality and adherence to international industry standards.

End Usage of Corrugated Containers

When ordering corrugated containers, consider how they will be measured and used:

Consider Product Security

Packaging plays a critical role in protecting the products inside. The strength of the container depends on the grade of kraft paper used in manufacturing. A reliable corrugated box manufacturer will have specialists and engineers who can help determine the optimal box strength and material composition for your needs.

Discuss with your manufacturer the ideal Edge Crush Test (ECT) rating for your boxes. The ECT measures a container’s compressive strength by applying pressure to the edges of the corrugated board, helping manufacturers produce stronger, more efficient packaging with minimal material waste.

The Box Maker’s Certificate (BMC) is a seal that has traditionally been used to indicate a box’s strength in compliance with industry regulations. However, the BMC is becoming less relevant, as it is not legally required and can create additional liabilities for shippers. While the presence of a BMC may indicate professionalism, it is not essential, especially for manufacturers using on-demand packaging systems or other modern production methods.

Consider Your Brand

A company’s packaging directly influences its brand image. Well-designed packaging enhances customer perception, while poor packaging can damage brand reputation. Consider how your corrugated box design, materials, and printing choices align with your brand identity and customer expectations. The right packaging not only protects your products but also reinforces brand recognition and enhances the overall customer experience.

Proper Care for Boxes

Moisture compromises one of the key advantages of corrugated boxes—durability. Keeping corrugated boxes dry is essential to maintaining their structural integrity and ensuring long-term usability. Exposure to moisture can weaken the material, causing it to lose strength and collapse under weight or pressure.

Corrugated fiberboard should always be handled with consideration for its anisotropic properties. Anisotropic materials exhibit physical characteristics that vary based on directionality and orientation. In the case of corrugated fiberboard, its behavior depends on the alignment of macromolecules, the flute structure, and the overall grain direction. Improper handling against these natural orientations can reduce strength and performance. Consulting with your corrugated box manufacturer will help ensure that you store, transport, and utilize corrugated fiberboard in a manner that aligns with its anisotropic nature rather than working against it.

Corrugated Box Terms

Box Plants

 Factories that manufacture corrugated and/or cardboard boxes, producing a variety of packaging solutions for different industries.

Cardboard

 A heavy paper-pulp-based board that may or may not be corrugated. To be classified as "corrugated," the board must contain fluted paper with air pockets between its outer layers for added strength and durability.

Converting Machines

Machines that transform flat corrugated boards into finished boxes. Common types include flexo folder gluers and die cutters, which cut, fold, and assemble boxes into their final form.

Corrugated Boxes

Containers made from corrugated material, featuring a fluted inner layer sandwiched between two flat linerboards for enhanced strength and cushioning.

Corrugated Paperboard

A material composed of two stiff sheets of paper joined by a middle layer of pleated, fluted paper, creating a lightweight yet strong structure used in packaging.

Corrugating Medium

The wavy, fluted paper layer inside corrugated paperboard, providing rigidity and shock absorption.

Corrugating Rolls

 Gear-like cylinders that shape flat paper into a series of waves or "flutes," forming the corrugated structure of fiberboard.

Die-cut Machines

 Machines that precisely cut corrugated board into custom shapes and patterns, which can later be folded into box designs tailored for specific products.

Flutes

 Ridges pressed or folded into paper, similar to pleats, that provide strength and cushioning in corrugated packaging. Flutes come in sizes A, B, C, E, F, and microflute, with C-flute being the most common.

Liner

 Also known as paperboard, this material resembles the brown paper used in grocery bags and forms the outer layers of corrugated fiberboard.

Single Face Web

A continuous sheet of flat paper with fluted paper glued to one side, often used for protective wrapping or lightweight packaging.

Web

 A long sheet of paper on a roll that is drawn into corrugating rolls to begin forming corrugated paperboard.