What Is Corrugated Packaging? Pros and Cons

If you thought that all packaging was the same—think again! There are many different types of packaging, and learning the ins and outs of it can become quite overwhelming if you try to do it alone. Thankfully, BoxGenie is here to help you learn about all the different types of packaging so that you can find the right option for you. 

Today we are going to be covering corrugated packaging. So keep reading for everything you need to know about this type of packaging, as well as the pros and cons so that you can weigh them out for yourself and determine if this option will work for you.  

What Is Corrugated Packaging?

Corrugated packaging is a type of packaging that is made up of several different layers of material. There are two different components of corrugated packaging: a liner and a medium. The liner is a thin piece of cardboard, whereas the medium is a type of fluted paper that is folded accordion-style. In most cases, there are two liners placed on either side of the medium. This design aims to provide more insulation and durability for the package’s contents while still being lightweight and affordable. 

How Is Corrugated Packaging Different?

After hearing this description of corrugated packaging, you may be wondering how it differs from other types of packaging. Other types of packaging usually consist of just a single layer of thick paper stock or heavy paper pulp. This is the type of packaging that you usually see on items on the shelf at a store that have already been shipped out or don’t need a lot of protection. 

Corrugated packaging, on the other hand, is typically what you think of when you think about a shipping box. This is because these types of items usually need more protection to keep them safe and secure throughout the shipping process. 

Pros And Cons Of Using Corrugated Packaging

Like anything, there are both pros and cons of using corrugated packaging. Depending on your business, your products, and your budget, corrugated packaging might be the best option for you so long as you weigh out the pros and cons. Here’s a breakdown to help you figure it out:

Pros:

• Corrugated packaging comes in many different shapes, sizes, and varieties so that you can easily find the perfect shipping option for you. More on that later! 
• Corrugated packaging is totally recyclable and is environmentally-friendly. This is important to consider if you’re a green company or want to appeal to environmentally-conscious consumers. 
• Corrugated packaging is still lightweight despite the multiple layers, making it easy to pack and transport without breaking your back or spending a fortune. 
• Corrugated packaging is durable and protective. Depending on the type and design, it can be tear-proof and crush-proof, making it ideal for rough shipping environments that may damage other types of packaging. 
• Corrugated packaging can feature printed designs, making it ideal for brands who are looking to create branded packaging that will appeal to their customers and promote their business at the same time. 
• Corrugated packaging is made from raw materials, making it an affordable option—especially when buying in bulk. 

Cons: 

• Corrugated packaging is not weatherproof and can be affected by extreme weather such as rain and snow. 
• Corrugated packaging can become deformed or lose its shape if under extreme pressure. 
• Corrugated packaging, while recyclable, is generally not reusable and high quantities will need to be purchased for one-time-use rather than multiple uses. 

Types Of Corrugated Packaging

As mentioned previously, one of the biggest pros of corrugated packaging is that there’s so much variety available. That being said, variety can easily become confusing and overwhelming if you don’t know what you’re looking for. Thankfully, we are here to help guide you on some of the different types of corrugated packaging so that you can choose the best option for your brand and your products:

Flute Size: We talked about fluting before as one of the main components of corrugated packaging, but there’s really more to it than that! For example, there are many different flute sizes available for corrugated packaging that contributes to the overall strength of the box itself. Here are the different flute sizes available for corrugated packaging:

• A flute: Has a thickness of about 5 millimeters for fragile products that need a ton of cushioning during the shipping process. 
• B flute: Has a thickness of about 3.2 millimeters and is commonly used for inner packaging components to protect and insulate different products within a single shipment. 
• C flute: Has a thickness of about 4 millimeters and is the most commonly used flute size within corrugated packaging since it’s not easily compressed or crushed throughout the shipping process. 
• E flute: Has a thickness of about 1.6 millimeters and is ideal for high-quality printing when dealing with products that may not need that much protection during the shipping process. 
• F flute: Has a thickness of about 0.8 millimeters, making it the thinnest and stiffest flute size. This flute type is commonly used in the retail arena as it has high printability and can easily impress customers from on the shelf. 

Board Types: Within corrugated packaging, there are different arrangements of the liner and medium components, leading to different board types. Here are the different board types and arrangements available for corrugated packaging: 

• Single-face: Consists of a single fluting and a single liner that’s only placed on one side. This is typically used in inner packaging components for additional insulation and protection.
• Single-wall: Consists of a single fluting placed in between two sheets of liner. This is the most common type of board used within corrugated packaging since it’s durable while still being lightweight and cost-effective. 
• Double-wall: Consists of two layers of fluting placed in between three different sheets of liner. This type of board is ideal for shipping heavy products due to its increased durability and strength. 
• Triple-wall: Consists of three layers of fluting placed in between four different sheets of liner. This is the thickest and strongest type of board and is ideal for shipping extremely heavy items that require special handling throughout the shipping process. 

Box Styles: Within corrugated packaging, there are also different box styles that are ideal for packaging all different types of objects. The options here are really limitless, but here are some of the most common corrugated box styles for custom packaging:

• Mailer Box: This type of box is sturdy and durable —yet stylish! It features dust flaps that keep the entire box totally safe and sealed from the elements. This type of box is ideal for e-commerce or even subscription services.
• One Piece Folder Box: This type of box is easy to assemble as it’s made from one single piece of material. This type of box is ideal for shipping small orders or flat items. 
• Shipping Box: This type of box is more than just your classic cardboard box. It’s durable and can be printed on to show off your amazing brand to your customers before they even open it. 

Should You Use Corrugated Packaging?

Now that you’re well-versed in corrugated packaging, it’s time to decide whether or not you should use it. Obviously, the answer to this question will depend on a lot of factors such as your budget, your products, your shipping process, etc. That being said, corrugated packaging can be a great option for a lot of businesses. If you’re still unsure or would like some more guidance on other packaging options, then we suggest you reach out to the experts. 

BoxGenie, for example, has been in the packaging game for almost 50 years! Over that time, they have been trusted by over 2,000 big brands to help them solve their packaging woes as well as design top-notch custom packaging to grow their brands. 

So before you go the cheap route with low-grade plain paper packaging, reach out to BoxGenie. They are able to help you determine what types of packaging you need and what will work best for you. Since they are family owned and operated, they understand what it’s like to be a small business simply trying to make dreams come true—and they are there to help you achieve this through amazing custom packaging! 

Conclusion

As you can see, there are many different pros and cons of using corrugated packaging. In most cases, however, the pros will outweigh the cons, making it an excellent option to ship a wide variety of different items. That being said, not all corrugated packaging is created equal, and it may be a good idea to consult with the experts at BoxGenie if you want more information on the different types available as well as different design options to really show off your brand. 

Sources:

1. https://www.smallbusinessbonfire.com/eco-friendly-packaging/
2. https://www.forbes.com/sites/forbesagencycouncil/2020/04/22/free-or-low-cost-ways-to-promote-your-business/
3. https://www.business2community.com/marketing/packaging-can-make-or-break-your-marketing-strategy-02226690