Corrugated cardboard is one of the most widely used packaging materials, utilized to package a vast array of products worldwide. It is mass-produced everywhere and appears to be a single-layer material with a consistent thickness level. But if you inspect a cardboard sheet closely, you will find that it consists of multiple layers.
Therefore, the construction of this cardboard differs from that of ordinary cardboard. Corrugated material is made of three layers. There are two plain layers and a wavy layer in between. In this blog, we will delve into a detailed discussion on the structure of corrugated cardboard and its manufacturing process.
Corrugated cardboard construction works on a very simple idea. Think of it as a sandwich: fluted material being the filling, acting on two inside or outside layers of paper, capable of being termed as the bread. This simple construction holds the magic of strength and versatility in the smooth and magnificent act of making corrugated cardboard.
The first to be made is the fluted sheet at the centre, which is termed fluting in a simpler way. The fluted material, with its valleys and bumps, contributes significantly to the cardboard's unique strength and rigidity. Then, this fluting is adhered to the two outer layers of paper, namely the inner and outer liners, by convention, which are traditionally classified as liners. It is this precise gluing that allows two elements to attach into a composite material that is more than the sum of its parts.
Through this blend, the Light Corrugated cardboard achieves a fine balance between strength and flexibility, making it better suited for the demands of the packaging market.
It is Kraft paper that is both strong and useful, and hence, it is the choice made whenever it comes to outer liners in corrugated packaging. This paper is primarily derived from softwood trees, "Virgin" fiber, which is a raw material directly produced from the resource. This safety feature gives it exceptional strength, making it a perfect fit for strong cardboard packaging. It features a surface texture that lends itself beautifully to printing, enabling the customization of brand imaging and labeling on Kraft paper. The industry is now moving towards Kraft with responsible sourcing, as there is a higher demand for sustainability in the packaging industry, which helps keep it healthy for future generations.
The test paper consists of two layers; its quality is typically referred to as duplex formation. The test paper has recycled fibers and, consequently, possesses a lower strength value than Kraft paper. Although not as strong as Kraft, Test paper is cheaper, making it a cost-effective option for packagers and also an inner liner material used in cardboard packages. The test paper won't print the same as Kraft, although it finds applications where high strength is more essential than aesthetics.
The type of wall used to make the material known as cardboard has a wave-like shape, and this curvy shape is crucial in determining its strength, durability, and protective capability. Knowing the different types of walls is essential for every individual when choosing packaging, so that it can meet individual product needs and provide optimal protection and presentation throughout the supply chain. These are:
The most elementary type of corrugated cardboard is a single-wall board, which consists of two liners covering a fluted centre. It is the type of corrugated board most often used; however, it typically lacks the necessary rigidity for heavy-duty applications and is prone to bending along the fluting.
To address the shortcomings of single-wall boards, double-walled materials are available. They typically come as another whole fluting section and liner for increased strength and rigidity. Double walls provide enhanced protection for heavier products during delivery and also offer additional impact resistance during transit. Suitable for various packaging needs.
For items that require even higher standards of protection, triple-walled or Tri-Wall cardboard is used. This language features an additional layer of fluting, which generally provides increased strength.
For cardboard packaging that delivers a superb level of protection, quadruple-wall cardboard sheets are used. These are only used to package fragile goods. They are uncommon and are only used in specific industries. This cardboard material is made of four layers of fluting for robust protection.
If you're looking for one of the thinnest fluting options, consider the F flute. It will provide a thickness of approximately 0.7 mm. F flute offers excellent printability for intricate branding or graphics, and has good strength. With approximately 128 flutes per foot, F flute will provide a robust yet delicate packaging option for lightweight items, such as cosmetics, electronics, or specialty food products.
On the lightweight end of things is E Flute, an extremely fine flute with a thickness of approximately 1mm to 1.5mm. The E flute features thin flutes that are closely spaced to produce a high-quality, smooth finish, resulting in excellent printability. It is commonly used in packaging with intricate branding and graphics. It offers excellent crush and compression resistance, useful for lightweight retail cartons. The E flute, however, would be inappropriate in a single-walled carton to provide weight for heavy products. E flute has approximately 90 flutes per square foot.
The B-flat flute is one of the most popular flute styles in the world, offering both versatility and dependability. The B flute has a thickness of approximately 3mm, providing both strength and flexibility. This flute type can be easily sliced through by cutting machines and can be cut into any shape, making it a versatile material for packaging. B flute contains 47 flutes per square foot.
C flute measures 3.5mm to 4mm thick and offers increased compression strength compared to B flute due to its thicker gauge, allowing for increased stacking and making it suitable for lightweight products. C flute is favoured for packaging that requires additional protection in transit. C flute has approximately 39 flutes per square foot.
A flute is thicker in profile, measuring approximately 5mm in height. It features excellent cushioning and shock absorption to protect fragile items during transit. A flute has more space due to its larger size, allowing for high-quality graphics and branding. C flute has approximately 33 flutes per square foot.
EB flute consists of a double-wall layer of E flute and B flute. EB flute provides a great balance of strength and printability, offering value in various packaging applications. The EB flute has a thickness of approximately 4mm to 4.5mm, which enhances transit protection and provides a high-quality printing surface.
So, the clever "sandwich" of paper layers is not a flimsy material at all, even if it seems so, and it is sturdy enough to keep your packages safe and products protected during delivery. Whether it's a single-wall box for your online order or a triple-wall box holding industrial parts, corrugated board is designed to withstand impacts, absorb shocks, and remain strong throughout the journey. It might have a lot of visual appeal, but it's a practical packaging material suited for modern shipping.
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