Types of Corrugated Boxes
Corrugated boxes are made of corrugated paper which is a versatile and cost-effective shipping and packaging material. Corrugated paper is composed of two thinner linerboards with a fluted paper layer in between them known as the corrugating medium. This structure allows corrugated boxes to be lightweight yet strong and protective.
There are different types of corrugated boxes designed for various applications. The main categories are:
Regular Slotted Containers (RSCs)
RSCs are the most common type of corrugated box. They are made from one piece of corrugated board with flaps on the top and bottom. The flaps allow the box to be folded easily without gluing or taping. RSCs are used for products that fit conveniently within the box dimensions.
Half Slotted Containers (HSCs)
HSCs are similar to RSCs but they have a half-slotted flap on the bottom instead of a full flap. The half flap folds over leaving the bottom side of the box open. HSCs are suitable for large or rigid items that need to slide in and out of the box.
Full Overlap Slotted Containers (FOSCs)
FOSCs have flaps that overlap completely to allow larger area coverage and greater stacking strength. The top and bottom flaps extend past the width of the box. FOSCs provide extra protection for heavy products.
Folder Boxes
Folder boxes have factory folded bottoms and folder flaps on the top. They can assemble quickly without gluing. Folder boxes allow easy access and display of products. They are commonly used for consumer goods, foods, and cosmetics.
Telescope Boxes
Telescope boxes consist of two main parts - a separate body and lid. The lid telescopes over the body to close the box securely. Telescope style boxes are ideal for shipping tall products as the height can be extended.
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Die Cut Boxes
Die cut boxes have intricate cuts and slots so they can be customized for specific purposes. Common die cut boxes include:
- Tray or Cameo Boxes - Have a fixed bottom and removable lid. Used for retail display.
- Collapsible Rigid Boxes - Can be stacked when collapsed to save space.
- Double Wall Boxes - Have three layers for heavy duty use.
- Produce Boxes - Designed with ventilation holes for fresh foods.
There are many other corrugated box styles available. The ideal design depends on factors like product dimensions, weight, fragility and stacking needs. Manufacturers can provide custom boxes tailored to your product requirements.
Regular Slotted Containers
Regular Slotted Containers (RSCs) are one of the most common types of corrugated shipping boxes. They are versatile and cost-effective making them a popular choice for many applications.
Design
RSCs have a simple and efficient design:
- Made from one piece of corrugated cardboard
- Four panels form the walls of the box
- Flaps on the top and bottom allow closing
- Flutes of corrugated medium run vertically
The panels fold to form the sides and ends of the box. The flaps fold in to close off the top and bottom. The flaps are usually the width of the panels and meet but do not overlap.
Sizes
RSCs come in standard sizes but can also be custom made. Common outer dimensions are:
| Length | Width | Height |
|---|---|---|
| 18 inches | 14 inches | 12 inches |
| 15 inches | 12 inches | 10 inches |
| 12 inches | 10 inches | 8 inches |
Benefits
RSCs are useful for many reasons:
- Lightweight and sturdy
- Made from recycled materials
- Easy to assemble by folding along score lines
- Do not require gluing or taping
- Can be printed with product labels and logos
- Stackable for efficient storage and transport
- Cost effective choice for many applications
Uses
Common uses for RSCs include:
- E-commerce shipping
- Retail product packaging
- Food packaging
- Industrial part shipping
- Consumer goods
- Postal and courier services
RSCs are the most widely used corrugated box style due to their versatility. They provide reliable protection and efficient transport for many products.
Half Slotted Containers
Half Slotted Containers (HSCs) are a type of corrugated box used for shipping and packaging. They are similar to regular slotted containers but have one distinctive difference - the half-slotted bottom flap.
Design
HSCs share the same basic design as regular slotted containers (RSCs):
- Made from one piece of corrugated cardboard
- Four panels form the walls
- Top flap for closure
The key difference is the half-slotted bottom flap that folds over leaving the underside of the box open. This allows convenient access for products to slide in and out of the box.
Sizes
HSCs come in a range of standard sizes such as:
| Length | Width | Height |
|---|---|---|
| 16 inches | 12 inches | 10 inches |
| 18 inches | 14 inches | 12 inches |
| 24 inches | 12 inches | 16 inches |
Custom sizes are also available to fit specific products.
Benefits
Half slotted containers offer advantages such as:
- Ability to slide products in and out
- Reinforced opening for strength
- Side loading and unloading access
- Faster pack and unpack times
- Reduced product handling
Uses
Example uses of HSCs:
- Automotive parts - Allow easy access to heavy components
- Appliances - Refrigerators and washers can slide out the open bottom
- Furniture - Tables and chairs can be side loaded
- Building supplies - Pipes and rods are conveniently loaded
HSCs are ideal for large, heavy, or awkwardly shaped items that benefit from side or bottom access. Their design minimizes product handling while allowing efficient loading and unloading.
Full Overlap Slotted Containers
Full Overlap Slotted Containers (FOSCs) are a heavy duty corrugated box style designed to handle heavier stacks and provide maximum protection. They use wider flaps that completely overlap to cover the full width and length of the box.
Design
FOSCs share the same basic slotted box design:
- Made from one piece of corrugated cardboard
- Four panels form the walls
- Top and bottom flaps
The distinction is in the flaps. FOSC flaps are wider than the box width, extending past the edges. This allows the flaps to overlap completely when folded in.
Sizes
Common outer dimensions of FOSCs are:
| Length | Width | Height |
|---|---|---|
| 32 inches | 24 inches | 18 inches |
| 36 inches | 24 inches | 24 inches |
| 48 inches | 40 inches | 36 inches |
FOSCs can also be custom produced to required specifications.
Benefits
Advantages of full overlap slotted containers:
- Increased stacking strength
- Full protection across box edges
- Reinforced corners
- Secure closure of flaps
- Minimizes box bulge
- Ideal for heavy, dense products
Uses
Example applications:
- Metal parts and machinery
- Large electronics like TVs and copiers
- Appliances - refrigerators, stoves, etc.
- Automotive components
- Building materials like tools or hardware
FOSCs are designed to handle the demands of heavy duty distribution and storage. Their strength makes them suitable for dense or bulky products.
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Benefits of Corrugated Boxes
Corrugated boxes offer many advantages that make them a versatile packaging solution for countless applications. Their unique structure combines strength, protection, efficiency, and cost-effectiveness.
Protection
The layers of linerboard and corrugated medium provide cushioning to safeguard contents:
- Absorbs impacts and shocks during handling
- Insulates against temperature extremes
- Water resistant
- Prevents damage to fragile items
Lightweight
Despite their strength, corrugated boxes are lightweight:
- Weigh less than alternatives like wood, metal or plastic
- Save on shipping costs with less weight
- Easier to handle and transport
- Reduce worker injuries from heavy lifting
Cost Effective
Reasons corrugated boxes are economical:
- Made from recycled paper waste
- Inexpensive to produce
- Efficient storage and transport saves costs
- Reusable/recyclable further improves value
Customizable
Design options include:
- Various styles and sizes
- Custom shapes and dimensions
- Printing and graphics for branding
- Interior dividers and supports
- Special coatings
Eco-Friendly
Sustainable merits:
- Made from renewable resources
- Recyclable and biodegradable
- Reuses waste paper
Strength and Durability
Construction lends structural integrity:
- Multi-layered walls
- Withstand compression and impacts
- Stable and rigid
- Resists punctures and tears
Corrugated boxes hit the mark for protection, efficiency, sustainability and cost-effectiveness.
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Strength and Durability of Corrugated Boxes
A key benefit that makes corrugated boxes so popular is their inherent strength and durability. The unique structure provides protective cushioning while remaining rigid and sturdy enough for stacking and storage.
Corrugated Construction
The layers that make up corrugated board contribute to its strength:
- Inner and outer layers of linerboard made from kraft paper
- Middle layer of corrugating medium with fluted paper
- Adhesive bonding the layers together
This multi-layered build gives corrugated boxes impact cushioning and compression resistance while maintaining a rigid, geometric shape.
Compression Strength
Corrugated boards can withstand high compressive forces:
- Fluted medium disperses force throughout box
- Inner linings prevent buckling
- Boxes maintain shape and integrity
This compressive strength allows for stable, secure stacking for transport and storage.
Bursting Strength
Boxes resist bursting forces:
- Wall structure prevents tears
- High tensile strength of kraft paper
- Good for fragile contents
Impact Resistance
Cushioning properties protect from impacts:
- Fluted medium absorbs shocks
- Prevents damage to contents
- Maintains box shape
The combination of durability, strength, and cushioning makes corrugated an excellent packaging material for transport and distribution.
How Corrugated Boxes Can Help You Save Money On Packaging And Shipping?
Corrugated boxes are an excellent choice for businesses looking to save money on packaging and shipping. Here are some ways they can help:
Advantages of Corrugated Shipping Boxes:
Overall, corrugated boxes provide a practical, cost-effective, and environmentally friendly packaging solution that ensures product protection and durability.
How Are Corrugated Boxes Made And What Materials Are Used?
Corrugated boxes are made up of sheets containing three or more layers. The main materials used to make corrugated boxes are paper, steam, and adhesive. The first step in the manufacturing process is passing Kraft papers through a corrugating machine, which creates the fluted middle layer by pressing the paper between two corrugated rollers. The fluted paper is then glued between two flat sheets, creating the corrugated cardboard. The cardboard is then cut and folded into the desired shape and size to create the final corrugated box product. The raw material for making corrugated boxes is brown Kraft paper. Overall, the manufacturing process for corrugated boxes involves pressing and gluing layers of paper to create a durable and versatile packaging material.
