A corrugated box is a paper packaging container made from a wavy inner layer, called the flute or corrugated medium, bonded to flat outer layers called liners. The flutes help keep the liners apart to stiffen the board, while the spaces they create can cushion contents. Box construction and design vary, so the right choice depends on the product and the way it will be stored, handled, and shipped.
What is corrugated board made of?
Corrugated board combines a fluted paper medium with one or more flat linerboard facings. The arched flutes separate the liners, increasing the board’s bending rigidity. The space between them can also provide cushioning and some insulation from sudden temperature changes.
Corrugated board is often called “cardboard” in everyday speech, but the terms are not precise synonyms. Corrugated board has a fluted layer; solid or folding paperboard does not.
How do single-wall, double-wall, and triple-wall boxes differ?
The names describe how many fluted mediums and flat liners make up the board:
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- Single-face: one fluted medium bonded to one flat liner.
- Single-wall: one fluted medium between two liners; also called double-face board.
- Double-wall: two fluted mediums separated by three liners.
- Triple-wall: three fluted mediums separated by four liners.
These are board constructions, not box styles. A box can be cut and assembled in different ways while using a particular wall construction.
What do the flute letters mean?
Flute letters identify approximate profile families. They are not universal strength ratings: flute dimensions can vary among manufacturers and corrugator designs. The Fibre Box Association gives these approximate North American counts per foot:
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| Flute profile | Approximate flutes per foot |
|---|---|
| A | 33 |
| B | 47 |
| C | 38 |
| E | 90 |
| F | 125 |
As a general tradeoff, larger profiles tend to offer more cushioning and vertical compression strength, while smaller profiles tend to support sharper graphics. These tendencies do not establish how a finished box will perform; its construction and intended conditions matter too.
Which corrugated box styles are common?
Box style refers to the design used to cut and assemble the package. Common families include slotted boxes, telescope boxes, folders, rigid or Bliss boxes, self-erecting boxes, and interior forms. The regular slotted container (RSC) is a familiar example from the slotted-box family.
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For communicating a design, FEFCO maintains an internationally applied code that assigns numbers to common corrugated packaging constructions. Its site describes the 12th version as reflecting industry changes and adding more than one hundred designs, including a series related to retail and e-commerce. A code can make it easier for buyers and suppliers to identify a design without relying on a long verbal description.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.How do you choose a corrugated box for shipping?
Start with the product and the full distribution cycle, rather than choosing by flute letter alone. ASTM’s selection practice says packaging attributes should match the intended use and conditions; a requirement based on only one segment of transport may not address the complete distribution and storage system.
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Assess the product and route
- Consider the product’s weight and fragility.
- Account for stacking and storage conditions.
- Consider how the package will be handled and the environmental conditions it may encounter.
- Think about the whole distribution and storage cycle, not just one leg of a shipment.
Specify material attributes or finished-box performance
A buyer may specify material attributes such as flute, edge-crush value, burst value, flat-crush minimums, containerboard weights, or thickness. Alternatively, a specification may address finished-box performance, such as compression strength or a rough-handling protocol. Which attributes matter depends on the application.
Material specifications alone do not guarantee sound manufacturing. ASTM recommends vetting proposed designs through samples and tests, as well as prototype packing and shipping. For demanding shipments, ask the box maker for relevant performance or test information and validate the package under conditions representative of actual distribution.
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Check the applicable standard edition
ASTM’s retrieved D5639/D5639M-20 page describes the selection practice, while its standards index also lists a D5639/D5639M-25 edition. Verify the active edition before citing a particular version in a purchase or packaging specification.
Quick Recap
Sources and further reading
- Fibre Box Association for corrugated board, flute profiles, and box styles.
- FEFCO for the corrugated packaging design code.
- ASTM D5639/D5639M-20 and the ASTM standards index for selection-practice and edition information.
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