Benefits Of Corrugated Cardboard Packaging

Corrugated cardboard boxes are used across retail, manufacturing, warehousing, e-commerce and home removals. They provide a practical combination of protection, low empty weight, straightforward assembly and a wide choice of sizes.

Boxes are also supplied flat-packed, allowing businesses to store packaging until it is required without filling warehouse space with assembled cartons.

Martins Mill Packaging supplies corrugated cardboard boxes for general packing, storage, postal dispatch and larger palletised consignments.

Cost-Effective for Everyday Packaging

Standard cardboard boxes are manufactured in commonly used sizes and quantities, making them a cost-effective option for many routine packaging tasks.

They can be used for:

• Warehouse storage
• Retail and e-commerce orders
• Postal dispatch
• Office files and documents
• Industrial components
• House and office removals

The lowest-priced box is not always the most economical choice. A carton that is too weak may fail during handling, while an oversized box can increase void-fill use, packing time and parcel dimensions.

The best value generally comes from selecting a box that closely matches the product’s size, weight and delivery requirements.

Available in Different Strengths

Corrugated boxes are available in several board constructions. The two most common are single wall and double wall.

Single wall boxes contain one fluted layer between two flat liners. They are relatively lightweight and commonly used for lighter, robust products and general storage.

Double wall boxes contain two fluted layers and three liners. Their thicker construction can provide additional resistance to crushing and impacts, making them more appropriate for heavier goods, stacking and demanding transport conditions.

The strongest box is not automatically required for every product. Choosing an unnecessarily heavy specification can add material, weight and cost without providing a meaningful benefit.

Lightweight and Easy to Handle

Cardboard boxes provide rigid protection without the weight of many wooden, metal or solid plastic containers.

Their relatively low empty weight can make them easier to:

• Move around a packing area
• Carry before filling
• Load into delivery vehicles
• Position on pallets
• Break down after use

The completed package must still be assessed according to its total weight. A lightweight cardboard container can become unsafe to lift once filled with dense products.

Businesses should avoid making boxes too heavy for employees, customers or couriers to handle safely.

Supplied Flat-Packed for Convenient Storage

Most corrugated cartons are supplied folded flat. This reduces the amount of storage space they require before assembly and allows packing teams to make up boxes as needed.

Flat-packed storage can be particularly useful for businesses holding several box sizes for different products.

Unused boxes should be stored:

• In a clean and dry area
• Off damp floors
• Away from leaks and condensation
• Flat or appropriately supported
• Where they will not be crushed by other stock

Moisture can weaken corrugated board and reduce its ability to withstand stacking and handling.

Easy to Assemble, Seal and Label

Standard boxes can usually be assembled quickly using suitable packaging tape. Their flat outer surfaces also provide space for shipping labels, handling instructions, product information and document wallets.

Depending on the contents, a complete packing setup may include:

• Packaging tape
• Bubble wrap or kraft paper
• Foam corner and edge protection
• Cardboard dividers
• Void fill
• Parcel labels and document wallets

The packing and wrapping range includes materials for cushioning, sealing and identifying boxed goods.

Tape should be applied to clean, dry cardboard. Dust, moisture and very low storage temperatures can affect how well some adhesives bond to the surface.

Suitable for Storage and Stacking

Correctly specified cardboard boxes can be stacked in warehouses, storage units and delivery vehicles. Their regular shapes also make efficient use of shelves, pallets and vehicle space.

Stacking performance depends on more than the board type. It can be reduced by:

• Overfilled or bulging boxes
• Excessive empty space
• Uneven weight distribution
• Boxes overhanging a pallet
• Damp or damaged cardboard
• Heavy cartons placed above lighter ones

Boxes should be filled so that the contents support the carton without placing excessive pressure on its sides. Fragile products may require cushioning or fitted inserts to stop them moving inside.

Versatile Sizes and Designs

Cardboard packaging is available in formats for products ranging from small postal items to complete pallet loads.

Options include:

• Single wall storage and dispatch boxes
• Double wall boxes for demanding loads
• Die-cut postal boxes
• Standard, Euro and half-Euro pallet boxes
• Made-to-measure cardboard boxes

This range allows businesses to choose a box that suits the dimensions and handling requirements of the product rather than adapting every item to one standard carton.

Custom Sizes for Unusual Products

Standard boxes remain the simplest option when a suitable size is available. However, unusual products may leave excessive empty space or fail to fit into conventional cartons.

Custom cardboard boxes may be useful when:

• The product has non-standard dimensions
• Large amounts of void fill are regularly required
• The same item is packed repeatedly
• The product needs internal support
• A limited or trial quantity is required

Martins Mill Packaging manufactures custom boxes at its Halifax premises using single or double wall board. Accurate product dimensions, packed weight and order quantity are needed before a suitable specification can be recommended.

Boxes Can Sometimes Be Reused

A cardboard box may be reused when it remains clean, dry and structurally sound.

Before reuse, check:

• The base and closing flaps
• The corners and side walls
• Areas damaged by old tape
• Signs of crushing or moisture
• Previous labels and barcodes
• Whether the box still suits the new contents

Old delivery labels should be removed or completely covered so the parcel is not misdirected. A weakened box should not be relied upon for heavy, fragile or valuable goods.

Recycling Used Cardboard Boxes

Cardboard boxes are commonly accepted by paper and card recycling services. Businesses should follow their waste contractor’s instructions and keep cardboard separate from general waste where required.

Before recycling:

• Empty the box completely
• Remove plastic and polystyrene inserts
• Remove excessive tape where practical
• Keep the cardboard clean and dry
• Flatten boxes to reduce storage volume

Wet, heavily contaminated or coated cardboard may not be accepted through the same recycling route. Businesses should confirm local arrangements with their authorised waste collector.

Limitations of Cardboard Packaging

Cardboard is versatile, but it does not suit every application.

Another material may be required where the packaging must:

• Remain outdoors for a prolonged period
• Contain liquids or fine powders
• Withstand repeated exposure to water
• Carry extremely heavy industrial products
• Meet specialist food, chemical or hazardous-goods requirements

Cardboard may also need to be combined with polythene liners, pallet wrap, strapping or protective cushioning according to the product and journey.

A Practical Option for Packing and Storage

Corrugated cardboard boxes are widely used because they are lightweight, versatile, easy to store and available in a broad range of sizes and strengths.

The best results depend on choosing a carton that fits the product and provides sufficient strength for its weight, stacking conditions and delivery journey.

Browse the available cardboard boxes, or contact Martins Mill Packaging with the product dimensions, approximate packed weight and required quantity for help selecting a suitable box.