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Triple Wall Packaging: An Overview

Large cardboard boxes vs small cardboard boxes: what are the benefits?

The benefits of getting the right sized box are clear: your goods will fit snuggly in, will be well protected and ready to be stored, transported, posted or archived. Here we take a look at what kinds of cardboard boxes are available in what sizes, how to choose the right ones for storage, postage or archiving and take a look at the benefits of large boxes and small boxes.

Small and big cardboard boxes

Large cardboard boxes vs small cardboard boxes: what are the benefits

The chief benefit large cardboard boxes have over small ones is that you can put many small cardboard boxes inside large boxes, shipping smaller items in bulk and giving the goods therein the protection of, essentially, two boxes.

However, large boxes and small boxes come in a wide variety of not only sizes but also formats and sizes, each designed to offer the perfect storage and/or transport solution based around the goods being shipped.

Naturally, for large and bulky items, you will need a large cardboard box – triple walled cardboard boxes. It’s great if, say, you have engine parts to dispatch. Similarly, 700mm double-walled boxes are designed to stack on pallets – they are standard Euro sized – and are ideal for the storage or transportation of all those items in smaller boxes.

Small boxes on the other hand have a varied array of uses. These come in a variety of sizes and can have reasonably secure lids – making them ideal for sending items through the post, as well as for packaging, storage and, as we shall see, archiving.

How do you store any item safely in archive boxes?

Storing items safely in archive boxes is a vital part of any business. Even in the digital era, it is essential to keep hold of paperwork pertaining to everything from tax to HR to publications and more – and this specific form of storage requires a specific form of box: the archive box.

Archive boxes are designed to be sized to accommodate the standard kinds of paper used in modern offices and, with their sturdy construction and closable lids are ideal for keeping out moisture, damp, dirt and dust – as well as stopping sunlight damage fading what is written on the paper.

To safely store items in archive boxes, you need to choose a box that fits your needs – so for easy access archive box folders have a closable lid and a finger hole for easy access. They can take A4 pages up to around a ream and are ideal for storage on shelves.

For archiving these box folders – for when they are no longer containing current paperwork that you need ready access to, but which you still need to keep – there are a range of cardboard archive boxes that can hold up to five archive files at a weight of 20kg. These have a closable lid offering great protection and handles for easy storage and retrieval.

Also in the pantheon of archiving boxes are Bankers Box transfer files, which are ideal for accessing information and publications that are needed often. They can be easily labelled and shelved and have easy access for users. Bankers Box transfer files can also be archived, in special Bankers Box two-piece cardboard archive file boxes, which are also ideal for storing lever-arch files, ring binders and foolscap magazines. Remember always label your boxes so that you – and others – knows what is where.

For all other archiving demands – from lose papers, to files to magazine and more – there are Snapcase two-piece cardboard archive boxes, which are designed to allow for maximum storage and easy access. They come with handles and a strong base so are ideal for moving things around and the sturdy lid adds protection. And lids are really important, as we shall see shortly.

What are the best boxes for postage?

Thanks to the growing hunger for buying things online, the cardboard box is most popular, and is the most practical – you can buy specialist boxes for postage. The best boxes for postage have to offer a range of things: they have to offer strength and protection for the goods inside, they have to be durable enough to withstand handling and transit, they have to be tough enough not to come apart when being bumped and they have to provide ample space for labelling for addresses and postage franking.

What are the best boxes for storage

With this in mind, there is quite a choice to be made when looking for a box for postage for your items.

The basic postal box is made from ridged flute corrugated postal board, which offers strength and protection for the goods inside when in transit. They also have an easily closed, locking flap that is secure, as well as neat and smart looking. These boxes offer all that you could hope for in a postal box: strength, durability and a sealed lid.

With the growth of ecommerce, ever more complicated and unusual things are being mailed, so postage boxes also come not just in a range of sizes, but also in a range of formats. For starters there are flat ones, made of the same tough corrugated card, designed for anything flat – and can be a great alternative to mailing bags.

Book boxes, meanwhile, are specifically designed for the postage of books, complete with sealable flap and sides to protect the books in transit.

If you are looking to post delicate items such as mugs or electronic devices, glass ware or ceramics then you need to choose postal boxes that will offer added protection. This is where foam-lined postal boxes and deluxe crash-proof postal mug boxes come in to play.

Foam lined boxes have a strong cardboard outer layer, but inside is lined with non-abrasive polyurethane foam that will completely surround what is in the box. Giving it excellent protection from the rigours of postage.

Mug boxes, meanwhile, not only have a crash-lock base, but also an inner cardboard fitting that holds the mug in place throughout the postal process with no need for void fill.

If you need a large box for posting then you need to choose a triple walled, corrugated box which provides delicate items with the shockproof, robust protection they need in the post.

One of the downsides of ecommerce is that things sometimes need to be sent back – and quick pack returnable boxes with adhesive strips are ideal for this. They offer easy and fast assembly, simply push the opposite corners towards each other and the base flaps lock together automatically. These strong and secure crash-lock base boxes close with an adhesive strip so there is no need for tape or glue.

The boxes are easy for customers to open and re-seal; simply pull the tear strip to open then secure the box using the second adhesive strip and it is ready to be returned.

Sometimes a postage box needs to be, well, not a box. For flat items such as maps or charts, textiles or prints, or long or cylindrical objects, postage tubes offer a great postage solution – they are strong both laterally and longitudinally and come with a tough plastic end cap that protects the ends and adds strength to the whole tube.

The benefits of cardboard boxes with lids

While end caps are essential to the integral strength of a postal tube, cardboard boxes with lids also offer many benefits for those looking to post, transport and store items. Cardboard boxes with lid features are ideal for storage, postage and transit as the lid protects the items inside from impact, moisture, dust and dirt. It also stops things falling out.

Having a lid on your box also means that you can stack them on top of the other. The lid also provides an ideal canvas in which to write what the contents is or to put an address label or postage franking if it is for posting.

Looking for the best shipping boxes?

Read the guide >>

Storing items in extra-large cardboard boxes

Extra large carboard boxes have to be innately strong to support themselves and to handle the kind of heavy loads that you want to store or transport in them. For this reason, extra large cardboard boxes are constructed from triple walled, corrugated card and can handle loads of up to 500 kg – the weight of a small cow.

It is best to pick large cardboard boxes that come in Euro or Chep/UK pallet sizes, as this makes them much easier to store and transport en masse. They are also strong enough to with stand the strapping needed to palletise such boxes, especially if you put strapping protectors on them.

These boxes are the expert’s choice when shipping large goods such as machine parts, domestic appliances, builder’s tools and construction products.

Types of cardboard packing boxes

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Cardboard packaging boxes and flat pack boxes are a staple of the warehousing, transport and export function of any business. But there is more to the humble cardboard box than you’d think. They come in a variety of shapes and sizes, can handle a variety of weights and some even come with their own pallets attached.

So which box types suit your needs and how do you choose? Read on.

Types of cardboard packing boxes

Cardboard packaging boxes and flat pack boxes are a staple of the packaging industry. Mention ‘packaging’ to most people and they think boxes. However, they are more interesting – and useful and varied – than you might think. And getting the right box for your storage needs is crucial.

Getting the right kind of box for your business can help smooth processes, protect your products, expedite storage and, if you are using branded postal boxes to send out your goods, create the right impression about your company. So, choosing the right kind of box is more important than you think.

Cardboard packaging boxes come in a variety of shapes, sizes and can be made of a variety of materials and constructions methods depending on how they are going to be used. They also throw up the issue of what types of tape and other fixings are needed to seal them, as well as coming with a range of inserts to allow for packaging specific items, such as bottles.

There are even a range of accessories such as wheels and handles to make storing and moving goods packaged in boxes easier. So how do you choose?

Single walled (left), double walled (centre) and triple-walled (right) ‘standard’ storage boxes

First of all there are a wide variety of boxes to choose from. At RAJA we offer a ‘standard’ box, which comes in a range of sizes as well as being single, double or triple-walled depending on what you need to store and how, as we shall come to. Triple-walled boxes are also known as loading cases and are really tough.

Single (left) and doubled-walled white boxes really stand out

There are also ranges of boxes with single, double and even triple walled boxes that come in white, that stand out and are excellent for getting your consignments noticed or for when you really need handling instructions to be obvious.

Flat packaging boxes offer a more tailored fit for a wide range of items

For more tailored needs and to pack a more diverse range of products, such as picture frames, mirrors, gifts, computers and industrial equipment, cardboard boxes come in a variety of shapes and dimensions, including many ‘flat’ boxes.

Flat boxes are great for postal deliveries of delicate and slim items

Many of these flat boxes are the kind of thing that many shoppers will be familiar with as what their goods arrive in when ordered online. One piece flat cardboard boxes are designed for slim products and, with the item placed in the centre and the flaps wrapped around, theses boxes leave an extended edge that provides impact resistance and corner protection.

Double wall, flat telescopic cardboard boxes

Telescopic boxes offer another tailored way to pack special items for storage or post

For the storage or transportation of items of varying sizes, telescopic boxes offer an ideal solution. Made up in two parts, with a lid that slides over a base, these boxes are great for accommodating different sized products as the lid can be slid as far down as required, always providing great protection for what’s inside. They look good too and, for postal items, offer a more novel unboxing experience.

Strong, triple-walled storage boxes are ideal when exporting

Do I need strong packing boxes?

While there are a variety of different sizes, shapes and finishes of cardboard packaging boxes, one of the main questions asked of flatpack boxes is how strong they are – or moreover, how strong do they need to be for a particular job.

Strong boxes are used for transport and storage and must be stackable

The strength of a cardboard box needed is determined by what is going in it and what are you going to do with it. For anything over 100kg, double or triple-walled large packing boxes are needed – up to a maximum of 500kg for some triple wall boxes.

If the boxes are to be loaded and stacked, or palletised, then they need to be strong, with supportive lids and corners. Many boxes are also used for transport and even export. These will be subject to stacking, moving and bumping and so need to be of strong specification.

The triple wall loading cases are made from triple wall top quality rigid flute corrugated board with 200gsm Kraft paper finish. Outer B flute 140gsm, 3-6mm thick with a 140gsm test; inner C flute 140gsm, 4-8mm thick with a 140gsm test and inner A flute 140gsm 5-10mm thick with a 200gsm test lining.

Cardboard cap and sleeve loading cases add even more protection and strength

For added strength, large boxes can also be purchased with cardboard caps and sleeves that allow for stacking and provide heavy duty protection. They are made of a stitched heavy duty corrugated sleeve, two end caps fitting top and bottom. These large cardboard boxes are easily collapsed for return or storage and can be easily stacked.

Capacitainer pallet boxes with Inka Presswood pallet

Some boxes come with their own pallet to help with protection when stacking

Some pallet sized cardboard boxes like the capacitainer pallet box come not only as flat packed boxes, but are also secured to their own Inka Presswood pallets with white plastic plugs, which fit in to pre-drilled holes on the base of the box and on the pallet. The boxes feature a drop down window making access to the contents quick and easy.

These boxes are made from double wall corrugated board (except CAPAC10 which is triple wall) and the Inka Presswood pallets are manufactured from processed recycled waste timber and are certified for export to: Argentina, Australia, Brazil, Canada, Chile, China, India, Japan, Mexico, New Zealand, South Africa, Taiwan and the USA.

Small packing boxes are often used for smaller, lighter gifts

For small packing boxes similar rules of thumb apply, but naturally they tend to be able to handle much less weight, instead being designed for gifts and much smaller, often more delicate items.

Choosing tape for packing boxes

Strapping or tape – how to seal a box

When putting items in boxes for storage, transport or postage it is key that they stay in the box. This is where tape and strapping comes in.

For a large packing box, many companies opt for strapping tape to seal boxes. Polypropylene hand strapping has a breaking strain of between 120 and 260kg and is easy to apply and won’t corrode. It is also extremely tough.

Pakit portable polypropylene strapping kits

Strapping kits are available to make it easy

Kits that feature a box of strapping – that is easily carried around the warehouse – and the tools to make applying it easy are also available, making it easy to strap up large storage boxes and pallet boxes.

Tape is great for smaller and medium sized boxes

For medium sized boxes and loads, packaging tape can be used to seal up boxes. It is really easy to apply – and easy to remove. It can also be branded with either the company logo, a message, or, if needed, a warning message.

Pre-printed FRAGILE self-adhesive paper tape

Tape can be used to seal boxes for storage and transport

So there you have it: cardboard boxes come in an almost infinite range of sizes and shapes and can handle loads up to 500kg – can be stacked, exported and can even come with their own pallets.

The other advantage they have is that they can be recycled and so are increasingly popular in our environmentally-conscious day and age. Happy packing!

Tip: How to dispose of your used cardboard boxes

>> Find out how

Want to know more about our wide range of cardboard packaging boxes?

For additional advice on cardboard packaging boxes in all their various shapes, sizes and forms, our Packaging Experts are here to help you find the right solutions and arrange next day delivery. Simply call us on 0800 542 44 28 or visit www.rajapack.co.uk.

The difference between plastic vs cardboard storage boxes

What are the differences between plastic vs cardboard storage boxes? For anyone remotely connected with shipping, packing or storage, the debate is timeless and all depends on what you are wanting to use them for, as well as personal preference.

On the one hand, cardboard storage boxes are tough and strong, easy to label, cost-efficient and can be recycled. On the other, plastic storage boxes offer a durable, water-resistant, strong and reusable alternative. How do you choose?

Cardboard boxes vs plastic boxes

Deciding on which is better, cardboard boxes or plastic boxes, really does come down to what you are looking to do with the box – and perhaps what you might want to do with the box after you have used it.

And you may be surprised by how environmentally-friendly each is when considered across its lifetime.

For starters, let’s look at cardboard storage boxes with lids. These offer protection for goods and items and, to a limited extent, can be stacked up securely. They are easy to label and, can be extremely cost efficient.

Cardboard storage boxes can be used for a wide range of uses. They can be used for sending fragile items through the post, be it books, mugs, DVDs and more. They can, with the right inserts, also be used to ship and store wine bottles, leveraging the natural protective qualities of strong cardboard to protect the contents.

In fact, cardboard boxes come in such a large variety of shapes and sizes – and with a cornucopia of opens and flaps – that they can be used for almost any storage or shipping purpose. There are long boxes, flat boxes, pallet boxes for stacking on pallets, as well as boxes for shipping and even specialist uses. You can even tailor your box to your product with our adjustable and telescopic cardboard boxes.

Telescopic boxes offer a customisable solution for storage, packaging and shipping

You can also use cardboard boxes to store – or indeed ship – documents, as well as cardboard boxes for archiving and even for easy access to goods through special openings.

There are also a wide variety of very specialist boxes for posters and even for clothes. Either being delivered through ecommerce or for storage or house moves.

And of course, there is also a wide variety of large cardboard boxes all sized 600mm+ to help you find the correct size box for your needs. You can even use RAJA’s own sizing tool to work out the best sized box for your goods – but more of that anon.

But cardboard boxes do have their drawbacks. While they are strong and cost effective, they are also limited in their strength and, perhaps more crucially for some storage and shipping options, not waterproof. The difference between plastic and cardboard storage boxes

This is where plastic storage boxes with lids come in. Plastic storage containers are more costly per unit – but they offer some advantages over cardboard boxes

For starters, plastic storage bins and boxes are generally stronger than their cardboard counterparts and, as a result, can be stacked higher. They can also hold heavier and more awkward items.

The main advantage, however, of plastic over cardboard is that it is waterproof and so is ideal for the storage of items that need extra protection from moisture or other environmental contaminants.

As a result plastic storage boxes can be used to store and ship all manner of small to medium duty items that need to be kept water tight and protected. The boxes with lids can be stacked and, when not in use and with the lids removed, can be nested.

For heavier duty storage and transportation, extra-tough, heavy-duty storage boxes that protect from impact as well as water and other environmental factors can also be used – offering a highly-reliable form of protection for a wide range of goods.

Plastic containers can also be used to store smaller, more delicate items, such as small components, stationery or other goods. Here plastic offers a resilient option that can be reused over and over again, where perhaps a cardboard alternative would wear out.

However, while plastic storage containers have a wide variety of uses and offer a greater degree of reuse, they are not so suitable for some applications. Plastic bins and containers are good for storage and shipping, but are often too expensive for one-off use in last mile delivery. In other words, you won’t find your Amazon book being delivered in a plastic box.

That said, some delivery businesses are toying with plastic – if they can get the boxes back. Plastic boxes, on the face of it, may seem to be less environmentally friendly than cardboard. However, if plastic boxes can be reused numerous times, they start to be less environmentally impactful. Recycling takes a lot of energy – even for paper – so getting more use out of a container can be more efficient, if you can sort out collection.

Types of cardboard storage boxes

While there are advantages to using cardboard or plastic storage boxes, depending on what you want to store where, let us focus for now on cardboard storage boxes, as they come in so many different shapes and sizes.

While for heavy duty and heavy weight storage and shipping needs, plastic is a clear winner, cardboard boxes aren’t as wimpish as you’d think, coming as they do in a wide variety of thicknesses.

For starters, there are single wall cardboard boxes, which are made of a single layer of tough corrugated cardboard and offer robust protection for your products with superior resistance to bursting, humidity and temperature change; in addition tapes adhere perfectly to the surface. The corrugated cardboard and puncture resistant Kraft outer works hard to secure your items, while still maintaining a smooth and clean finish for your adhesive address labels to stick to.

Singled wall cardboard boxes are strong, light and low cost way to store a wide range of items

These boxes are ideal for storing, packing and shipping of products and goods and are delivered flat packed for easy storage and transport.

Double wall cardboard boxes are tougher still for stacking and shipping of fragile objects

If that isn’t enough, there are also a wide range of double wall cardboard boxes, which are designed to be tough still. Double walled cardboard boxes are made from two layers of rigid corrugated fluting with a tough puncture resistant Kraft outer lining. This means that the double wall cardboard box retains its shape during shipping or storage and offers superior strength and durability over single wall cardboard boxes.

These sturdy boxes are suitable for a wide range of products from glassware, household fixtures and fittings to small electrical goods and can be stacked.

Triple walled storage offers a really tough way to store and ship even the heaviest items

If you need a really strong storage and shipping box, triple wall cardboard boxes have you covered. Manufactured from top quality rigid flute corrugated board with a 200gsm Kraft paper finish, these are ideal for heavy duty items such as metal parts, compressors, boilers, pumps, industrial tools and machinery. Recommended for shipping and exporting.

In fact, these boxes has been especially designed for metal parts, compressors, boilers, pumps, industrial tools and machinery our heavy duty triple wall boxes with a weight capacity of up to 500kg also come flat-packed for easy, space saving storage in your warehouse.

Conclusions

The debate over whether cardboard or plastic makes for a better storage box is not really a debate at all: it all depends on what you want to store, ship or archive. For heavy duty, long term storage, or to store things that are in repeat use, plastic storage boxes have the edge as their higher price delivers more value over time.

However, for one off shipping cardboard has the edge. With cardboard storage boxes coming in a variety of sizes and thicknesses, they offer the ability to ship and protect anything from a book right up to a compressor. The only thing that ‘weakens’ the case for cardboard is that it isn’t waterproof like plastic.

That said, which you want to use comes down to what you are packaging and what you want to do with it. There is a vast array of solutions to choose from – and we can help you choose.

Want to know more about the wide range of cardboard and plastic storage boxes?

For additional advice on storage boxes in all their myriad shapes, sizes and materials to meet all your packaging, storage and shipping needs, our Packaging Experts are here to help you find the right solutions and arrange next day delivery. Simply call us on 0800 542 44 28 or visit www.rajapack.co.uk.

Our favourite Cardboard Crafts for Halloween

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It’s almost that time of year – when the ghouls and ghosts come out to haunt us and trick or treaters visit. With Halloween fast approaching, we’ve been exploring some of our favourite cardboard craft projects with used packaging to make spooky decorations, creepy costumes and petrifying haunted houses. We’ve selected some of our favourites and detailed them below, so round up any leftover packaging and get crafting!

Source: https://pixabay.com/en/halloween-witch-s-house-the-witch-2893710/

All Hallows’ Eve?

You don’t have long to get your decorations up, pumpkins carved and costumes crafted! This ancient day dates back over 2,000 years, where it was celebrated as a Celtic festival called Samhain to mark the end of Summer. It was believed that it was at this time of year when the space between the world of the living and the dead blurred, and spirits would crossover at this supernatural time. Originally known as ‘All Hallows Eve’, over time the name evolved into ‘Halloween’ as we know today.

It’s more popular than ever too, with an estimated 25%* of us carving pumpkins and spending over £25million on them across the UK. But if you have any leftover packaging around, we know the value of a good cardboard box and after use they are great for craft projects. You can make some impressive Halloween decorations (even a cardboard pumpkin!) with some basic craft materials and a bit of creativity to save money and reuse materials.

Spooky decorations for your home

With a few cardboard boxes, some tape, glue and cutters there are no end of creations you can craft to add a spooky feel to your home. We’ve selected a few of our favourites below and listed the instruction videos so you’ve got everything you need to get started!

Cardboard Pumpkin Head

If you want a spooky pumpkin but don’t want to carve up a fresh one then take a look at this brilliant cardboard alternative. Taking a couple of cardboard boxes, you can cut out the entire shape from cardboard with a knife and then glue these together to make the impressive pumpkin head shape. Once you have it constructed, you can decorate with a bright orange paint and any other creepy decorations. Place a sheet of crinkled foil inside and you can illuminate it with an electric candle light for your very own jack-o’-lantern made from packaging!

Spooky Sweet Dispenser

For something a little simpler, this sweet dispenser made from a cardboard box by Box Yourself is a great little craft project to add a creepy vibe to your treats this Halloween. It’s easy to do and you only need a cardboard box, some paints, glue and a cutter to craft some facial features. It’ll be a great addition to any house this Halloween.

Cardboard Tombstones

For a haunting outdoor decoration take a look at these striking cardboard tombstones. So simple to make by taping a few sheets of cardboard and newspaper. Once you have the structure made, you can paint and decorate, adding creepy fun messages on the front for all to see when they approach your door.

PET-rifying Haunted Houses

Finally for the pet lovers out there (and we have quite a few in the office!) we love these cardboard haunted pet houses. We’ve listed a couple of our favourites below, whether you have a dog or a cat you can make a great little home for your furry friend with a spooky feel.

The DIY haunted dog house simply takes a few cardboard boxes, a bit of crafting and sticking to bring together a single or multi story haunted pet house. For decoration, you can be as creative as you like with pens and paints – they’ve even added cobwebs in the video below.

If you’re a cat lover, then this PET-rifyingly cute house takes a large and a medium sized cardboard box and turns them into an impressive structure. In the video they add roof tiles, shutters, gnarled trees and fencing with extra pieces of cardboard and paper which really enhances the spooky feel.

Please do let us know of any favourite Halloween craft projects of your own, post them in the comments below and we’ll be sure to take a look. If you’re a regular user of packaging and cardboard boxes and need any advice selecting and purchasing packaging, then our team of Packaging Specialists will be happy to help and answer and questions you might have. Simply visit www.rajapack.co.uk or contact our team on 0800 542 44 28, or sales@rajapack.co.uk.

*https://www.finder.com/uk/cost-of-pumpkins

When does a cardboard box become more than an essential packaging supply?

Corrugated cardboard boxes 101: What you need to know

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Cardboard is the one of the most popular packaging materials in use today, and the most well known is corrugated cardboard boxes, and we don’t expect that to change anytime soon. It’s lightweight, strong and resilient, offering excellent protection for almost any item. But did you know that it’s corrugated cardboard that gives boxes their strength?

Today we’re focusing on precisely that – the material that gives corrugated cardboard boxes their superior strength and resilience. In this post we’ll be covering everything corrugate related, including how cardboard boxes are made, when corrugated cardboard was invented and how it works, as well as tips on recycling; how to shred, cut and dispose of corrugate.

Corrugated cardboard boxes - What you need to know Image source: https://pixabay.com/en/cardboard-perspective-texture-467819

How is corrugated cardboard made?

First we’ll start with the basics – just what is corrugated cardboard? Put simply, it’s the thick, strong arrangement of card that makes up the walls of a cardboard box. It’s this combination of materials that gives cardboard their high strength and resistance to bumps, knocks and crushing.

The cardboard that makes it up is arranged in a concertina, zig-zag like like pattern which gives strength to both sides of the box. This is held in place and secured with a layer of paper on either side which is called the fluting. Fixed in place firmly with strong adhesive, it can be made of different types of paper such as Kraft or Test, and it’s these outer layers that keeps the corrugate securely contained inside. For more information about the inner liners and fluting, take a look at our beginner’s lesson in corrugate cardboard and cardboard in a recent post about cardboard box disposal.

How is corrugated cardboard made Image source: https://pixabay.com/en/corrugated-cardboard-boxes-flutes-2225141/

So, exactly when was corrugated cardboard invented? Its history goes back a long way – the earliest reports of it being patented were in England in 1856. Although it was not thought of as a packaging material at the time and was mainly used for other things such as hat lining!

The first recorded packaging and shipping patent for corrugate was in the United States and issued on December the 19^th, 1871, where it was used for wrapping bottles and glass lantern chimneys. In the years that followed it became a popular packaging material, with wooden crates and boxes replaced by corrugated paper shipping cartons from the early 1900s.

With the development of this resourceful material, cardboard boxes could be readily made for reliable shipping and storage, but how are cardboard boxes made? The process begins by making the inner corrugated board – this is done by a large machine called a corrugator. Board is fed into the corrugator, heated and pressed into the concertina form that we see above – this forms the central filling of the cardboard box wall. Two outer liners, the fluting, are then fed through and securely glued to the corrugate using very strong adhesive. Once the glue is set using steam, the flat complete board can be cut into large sheets of various sizes which are used to form the flat packed cardboard boxes that you receive from your packaging supplier. At RAJA we stock over 600 different sizes and types of cardboard boxes , so you can imagine the cutting and loading process can become quite complicated!

What is corrugated cardboard used for?

Corrugated cardboard can be used for various applications, the most common is to house items with the use of a corrugated cardboard box. But first, let’s understand just how does corrugated cardboard work? This innovative construction features three separate materials and gets its super strength from the combination of all 3 working together. In the centre, the concertina card is tightly but firmly packed within two layers of fluting and this gives strength across the width of the card to both sides of the material. It’s this concertina structure that makes the card super strong.

With many different types of cardboard box available, we often get asked which is the right one to use, and how thick is corrugated cardboard? The great thing about how it’s made means that many different types and strengths can be produced.

Some use thinner, more lightweight materials with a single layer of corrugate for a light and strong box – these are called single wall boxes. Others can use several layers of corrugate made from much thicker card. For these boxes, the material can feel as strong as steel! Our ultimate strength triple wall boxes can support up to an impressive 500Kg in weight, all from a few layers of cardboard!

We already know that corrugated board was patented for use as a shipping material in 1871, and this was for single side, single face corrugated board with one layer of paper on one layer of corrugate. But who invented corrugated cardboard? The patent was registered in New York City by Albert Jones – you can actually see the first patent for corrugate as this is hosted online, along with the description and technical information registered – a fascinating piece of packaging history!

Why is corrugated cardboard so strong?

Corrugate cardboard is so strong because of it’s internal structure, and this contributes to the same reason why corrugated cardboard is a good insulator. The main strength of corrugate comes from it’s concertina like zig zag shape. Being contained within fluting by strong adhesive, cardboard is strongest along the length of the material and it’s this structure that gives it strength to support both sides. And all between the fluting air is trapped and cannot move around, the layers prevent the air from escaping making it a poor head conductor.

Is corrugated cardboard recyclable?

Corrugated cardboard is recyclable, for additional information on RAJA and the environment why not take a look at our environmental FAQs and read on.

As a packaging provider we must be mindful of how our packaging materials can be recycled and in an environmentally responsible way. So, is corrugated cardboard biodegradable?

The good news is that yes, it is biodegradable. It will break down in the environment over time, though it can take a long time depending on the environment that it’s in. If it’s wet and broken up into small pieces then it will degrade much faster, so if you have a compost bin at your home or business then cardboard can be a great addition to your compost.

Boxes can be quite large once broken down particularly if they’re pallet or export boxes. If you don’t have a great deal of space to store them on site in between recycling collections, then you may wish to shred your cardboard.

If you want to know how to shred corrugated cardboard, it’s simple and straightforward. You could use an automatic cardboard shredder which perforates and converts corrugated cardboard into a strong, shock absorbent netting material which can be used as packaging. Alternatively, you can shred it manually by soaking it in water which makes it very easy to tear and cut through with normal scissors if it’s single or double wall. For triple wall, you might need something a little stronger like a box cutter detailed below, or some industrial scissors that offer more strength.

Even though it does break down, it’s always our preference to recycle cardboard when you can – all our boxes are made from 75% recycled fibres on average. Local recycling collections for paper and card are usually frequent and the recycling loop for corrugate is so efficient that used boxes can be recycled, remade and reused in just two weeks! Cardboard recycles very well, without loss of strength or rigidity so it’s an excellent material to recycle.

Crushed corrugated cardboard boxes ready to be recycled Image source: https://unsplash.com/photos/1PxGp8kkQyk

Corrugated cardboard is also great to use for packing – placing in boxes to separate items to hold them securely in place. The fact that it’s lightweight, easy to handle and cut means it’s perfect for many different uses. If you’re wondering how to cut corrugated cardboard then don’t worry, it’s easy. A small cutting knife, called a box cutter will do the job with ease and glide through corrugate easily.

What is non-corrugated cardboard?

Finally we’re looking at non-corrugated cardboard as an alternative. Non-corrugated cardboard is exactly the opposite of corrugate as you would expect! In this material, cardboard is simply layered on top of each other, in the similar way to how puff pastry is made. This can make the cardboard material smoother, so it’s good for printing striking visuals or designs onto.

It’s mainly used for lightweight products, presentation boxes and you may have encountered it in things like iPhone boxes or for other gadgets. Generally, it’s not recommended to be used as a serious packaging material, though can be cheaper than corrugate due to its simpler and more lightweight construction.

If you’d like more information about corrugated cardboard, our range of cardboard boxes and packaging supplies, or help on selecting the right cardboard packaging for your business, get in touch with our team of packaging experts who will be happy to help. Simply visit www.rajapack.co.uk or contact our team on 0800 542 44 28, or sales@rajapack.co.uk.

How to dispose of your used cardboard boxes

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With over 600 different sizes of cardboard boxes to choose from, we’re confident that we can supply a box to fit any size or shape of product. But once something has been successfully shipped the cardboard then must be properly disposed of.

Everyday at RAJA we get asked questions about how to recycle cardboard boxes or how to recycle cardboard boxes at home. These questions are so popular that we’ve decided to focus this post on exactly that, including useful info on where to recycle cardboard boxes.

How to dispose of your used cardboard boxes

Image source: https://unsplash.com/photos/fyaTq-fIlro

A beginner’s lesson in corrugate cardboard and cardboard

If you’re not familiar with cardboard boxes and what they’re made from then we’ve put together some brief info to get you up to speed.

Firstly, what does corrugate cardboard mean? This is the structure of the board and the combined inner layers of liner and fluting which gives boxes their rigidity and strength. All boxes we sell at RAJA are made from corrugate cardboard.

The layers of liner in a box are usually made from test paper which is a lower grade of Kraft and Kraft paper which is made from virgin fibres and is a higher grade. These liners provide strength and support to the fluting which runs between them and can offer some resistance from water and the elements. The material used here means you can write or print on the box for easy identification.

Finally, what is fluting? Fluting is the word used to describe the wavey cardboard that is between the two liners. It’s wavey shape gives strength to the liners that surround it and the direction and distance between the flutes can vary depending on the strength of the cardboard box. More waves means a box has more strength.

Can corrugated cardboard be recycled?

Corrugate board is one of the most popular types of cardboard we use, found in corrugated cardboard boxes and packaging where it offers excellent strength and resistance to knocks and bumps. The inner layer of corrugate, sandwiched between two layers of Kraft paper, make it strong and resilient.

The big question we get asked is “Can you recycle corrugated cardboard?” Absolutely! The great thing about corrugated cardboard is that it can be completely recycled and used to make other cardboard boxes and cardboard products. Recycling your used cardboard boxes saves the trees, energy and materials used in the manufacture of new boxes.

At RAJA we have a range of eco-friendly packaging, including our boxes which are made from 75% recycled fibres on average, and the ‘recycling loop’ for corrugate is so efficient that used boxes can be recycled, remade and reused in just two weeks!

Boxes flattened on pallets

Image source: https://unsplash.com/photos/qph7tJfcDys

So, our Sales team is frequently asked, where to take cardboard boxes to recycle them? Many councils now offer recycling boxes for homes (usually coloured green or blue) where you can place items such as paper, aluminium and cardboard including corrugated cardboard for regular collection. There are also local recycling sites across the country which accept corrugated cardboard for free.

You can check your recycling collections and find local recycling sites in the ‘Recycling Collections’ section of the government website, an easy to use page where you only need to enter your postcode. Other sites such as the Recycling Locator on recyclenow also make it easy to find information on where you can recycle locally.

Is cardboard biodegradable?

If a material is biodegradable then it naturally breaks down and decomposes in the environment in a way that doesn’t harm it. Food waste, for example is highly biodegradable usually breaking down naturally and safely in a short amount of time.

Cardboard is a biodegradable material – corrugated cardboard will break down and decompose naturally, though it can take a long time depending on the environment that it’s in.

It breaks down quicker if it’s wet and broken up into small pieces, and so is great for home composting if you have a compost bin. If you are disposing of it at home, then make sure to cut it into small squares and wet it through thoroughly. There’s lots of useful information online about how to prepare it for composting.

How to break down cardboard boxes

Once you’ve finished with a cardboard box, it’s quick and easy to break it down so that it can be properly stored, ready for recycling or prepared for compost.

The first thing to do is to remove all plastic or vinyl packaging tape from the box. This will have been used to seal it shut, and usually runs along the top and bottom flaps to keep it secure. This should easily pull off and can be disposed along with your normal rubbish.

If paper tape has been used to seal the box then you can leave this on as it can be recycled along with the cardboard box. If you’re composting then it will biodegrade along with the cardboard, so it’s safe to leave on. It’s what makes paper tape more eco-friendly than vinyl or plastic tape.

Sealing cardboard boxes with RAJA

Once the non-recyclable tape has been removed, then you can easily flatten the box out. Ensure the top and bottom flaps are straight (not at right angles to the box) and push the opposite corners together. The box should close up and you should then have a flat box which is much easier to store or transport. If you are recycling it, be sure to keep it in a dry place ready for collection as it can be very difficult to recycle and handle when wet.

Learn how to recycle your cardboard boxes with RAJA

Read How to Recycle Packaging Materials for more information on recycling packaging materials, and if you’d like more information about the range of cardboard boxes that we offer, any help or advice on purchasing packaging or the best way to dispose of it, then simply get in touch with our team of packaging experts who are on hand to help.

Simply visit www.rajapack.co.uk or contact our team on 0800 542 44 28, or sales@rajapack.co.uk.