Introduction: Why Corrugated Packaging Still Leads the Pack
In an age of advanced materials and high-tech solutions, one simple material still leads the way: corrugated cardboard. It’s lightweight yet strong, affordable yet highly customisable. This humble material has stood the test of time. It’s now the standard for everything from shipping boxes to retail displays.
According to the Fibre Box Association, over 95% of products shipped in the U.S. are packaged in corrugated board at some stage. Its dominance in e-commerce and retail is no accident. Corrugated board offers a perfect balance of strength, sustainability, and flexibility.
But what makes corrugated cardboard so effective? Why is it used for everything from online orders to store shelves?
In this article, we’ll explore its key properties. We’ll look at how corrugated board is made and structured. And we’ll explain why it remains the top choice for businesses that need strong, eco-friendly, and versatile packaging.
What is Corrugated Cardboard?
Corrugated cardboard (also known as corrugated board or corrugated fibreboard) consists of a fluted inner layer (the “corrugation”) sandwiched between one or two flat linerboards. This structure gives it incredible strength-to-weight ratio and impact resistance.
The wave-like flutes act as a cushion, absorbing shocks and providing rigidity without excess material. It’s used in custom cardboard boxes, die cut boxes, and even eco-friendly packaging options.
Key Properties of Corrugated Cardboard
Understanding the corrugated cardboard properties helps businesses choose the right material for their packaging needs. Here are the most valuable characteristics:
- Lightweight Yet Strong: Corrugated card offers excellent structural integrity while being easy to handle and transport.
- Shock Absorbent: The fluted design protects against compression and impact—ideal for shipping fragile or heavy items.
- Customisable: It can be cut, folded, printed, or laminated to suit branding and structural requirements.
- Recyclable & Eco-Friendly: Made mostly from recycled materials and 100% recyclable—an essential feature in today’s sustainable economy.
- Cost-Effective: Affordable even at scale, especially when compared to plastic or rigid materials.
Want more sustainable options? Explore our Eco-Friendly Solutions.
Types of Corrugated Cardboard Used in Packaging
Corrugated board is not one-size-fits-all. Different flute sizes and layers are used depending on the application.
- A-Flute (5mm)
Best for cushioning—commonly used in fragile or heavy-duty shipping.
- B-Flute (3mm)
Great for retail displays or die-cut designs due to its excellent crush resistance.
- C-Flute (4mm)
A middle-ground solution popular for cardboard boxes and general-use packaging.
- E-Flute (1.5mm)
Thin and lightweight—perfect for custom printed boxes, cosmetics packaging, or subscription boxes.
- Double Wall
Combines two flute types for added strength. Used for bulky or industrial products.
Use Cases: Industry-Specific Applications
Corrugated packaging is used across nearly every sector, thanks to its adaptability and protective qualities.
Retail & E-Commerce
From fashion to electronics, custom corrugated boxes protect products during shipping while offering branding opportunities with high-quality printing.
Food & Beverage
Corrugated board is widely used in takeaway boxes, bakery cartons, and beverage trays. It complies with food-safe standards and keeps perishables intact.
Industrial & Manufacturing
Heavy-duty die cut boxes made from double-wall board are common for machinery parts, tools, or bulk shipping.
Gift & Subscription Services
Brands can create fully branded, eco-conscious packaging using E-Flute corrugated card, enhancing the unboxing experience.
Corrugated vs. Standard Cardboard: What’s the Difference?
While often used interchangeably, cardboard and corrugated cardboard aren’t the same.
- Cardboard is a general term that may refer to thin, single-layer paperboard (like cereal boxes).
- Corrugated packaging refers specifically to multi-layered boards designed for structural strength and protection.
If you’re printing retail boxes or delivering breakables, corrugated is the professional choice.
The Role of Die Cut Corrugated Boxes
Die cut boxes allow for custom shapes, sizes, and openings. Using corrugated card in die-cutting provides strength without sacrificing design flexibility. These are ideal for:
- Display-ready packaging
- Custom inserts and compartments
- Easy-opening retail packs
Why Corrugated Packaging Is Also Eco-Friendly?
Businesses are under increasing pressure to offer sustainable solutions. Fortunately, packaging corrugated materials are:
- Made from recycled fibres (up to 80–100%)
- Biodegradable and recyclable
- Lighter than alternatives, reducing shipping emissions
- Accepted in nearly all recycling programmes in the UK
When you use corrugated board, you’re not just protecting your product—you’re helping protect the planet.
Why Choose Healey Packaging?
At Healey Packaging, we specialise in custom corrugated boxes that are strong, sustainable, and brand-ready. Whether you’re a startup or a national retailer, we provide:
- Bespoke box structures (regular slotted, die-cut, mailer, and more)
- CMYK printing for vibrant branding
- Eco-friendly materials with full recyclability
- Technical expertise to recommend the right flute and grade
- Fast turnaround times across the UK
Looking for something specific? We’re ready to assist with packaging tailored to your needs.
Conclusion: Corrugated Cardboard Still Reigns Supreme
Despite the rise of alternative packaging, corrugated cardboard remains the gold standard. Its unique properties—strength, versatility, and sustainability—make it indispensable for modern brands. From retail packaging to industrial logistics, there’s a corrugated solution for every need.
👉 Ready to elevate your packaging with custom corrugated boxes? Get a free quote now.
FAQs About Corrugated Packaging
Why is corrugated cardboard used for packaging?
Corrugated cardboard is strong, lightweight, and shock-absorbent—perfect for protecting items during shipping and handling. It’s also recyclable and customisable.
What is the difference between cardboard and corrugated packaging?
Cardboard typically refers to thin paperboard used for items like cereal boxes. Corrugated packaging includes a fluted inner layer and is much stronger and more protective.
What type of cardboard is used for packaging?
Corrugated fibreboard is the most common type of cardboard used for packaging. It comes in various flute sizes depending on strength and cushioning needs.
What does corrugated mean in packaging?
“Corrugated” refers to the wave-like fluted layer between linerboards. It gives the material its strength and cushioning properties.
