How to choose custom corrugated boxes
Corrugated board is two flat liners with a fluted layer between them, which makes it far stronger for its weight than flat paperboard. Choosing corrugated means choosing a flute, a wall count and a liner.
Sizes and styles
Corrugated covers shipping cartons, mailer boxes, lid-and-tray boxes and boxes with inserts. Pick the structure for how the box is packed and opened, then size it to the product. Large or heavy items often need a lid-and-tray or full-overlap style so the top and bottom carry the weight evenly.
Materials
E-flute (about 1.5 mm) is thin and prints well; B-flute (about 3 mm) is stronger and cushions better; double-wall combines two flutes for heavy contents or stacking. White-lined board prints brightest; kraft-lined board is more economical. See corrugated cardboard and recycled cardboard.
Finishes that work best
Corrugated can be printed directly (flexo or digital) or with a printed paper liner laminated on top for photo-quality graphics. Aqueous coating adds scuff resistance; matte lamination suits premium mailers.
Pricing drivers
Flute and wall count, box size, print method and quantity drive cost. Litho-laminated printing gives the best image quality but costs more than direct printing.
Before you order
- Weigh and measure a packed box. The right flute depends on the total weight, how far the box travels and how it is stacked.
- Decide where the box will be seen. A box that goes straight from a warehouse to a recycling bin needs strength more than print. A box opened by your customer is worth printing well.
- Allow for board thickness. Corrugated is thick, so inside and outside dimensions differ more than with paperboard. We quote inside dimensions so the product fits.
- Choose direct print or litho-lamination early. The print method affects the artwork, the lead time and the price, so decide before final design.
- Plan for moisture. Boxes stored in cold rooms or humid warehouses lose strength. Tell us about the storage conditions and we will suggest a stronger board or coating.
Minimum order and lead time
Most styles start at 100 units; some specialty styles have a higher minimum, shown on each product page. Production takes 7–10 business days after you approve the digital proof, and US shipping adds 5–7 business days. Rush production in 5–7 business days is available for an additional fee. Every quote includes a free 3D design and dieline, so you can check the structure before you order.
