Corrugated Cardboard – Characteristics and Applications
In the production of packaging, we use several different materials, each with its own unique properties. Among them are various types of board and corrugated cardboard. These materials are chosen not only for their durability but also for their versatility and printability, which is essential for high-quality packaging.
Types of Materials Used in Packaging
Cardboard: This is a multilayer coated paper with a weight ranging from 180 to 450 g. It is dedicated to small packaging such as cosmetic boxes, wraps, sleeves, folders, rigid envelopes, advertising wobblers, calendar backings, and overlays for laminated packaging. More information can be found in the “Solid Board” section.
Solid recycled board (beermat): This is a very rigid bookbinding material, made 100% from recycled paper. We use this material for the production of hard covers for catalogs, binders, display stands, and beer coasters. It also works perfectly for packaging board games.
Corrugated cardboard: This is the material we use most frequently when producing packaging. It is particularly valued for its strength-to-weight ratio, which makes it ideal for both standard and large-format packaging.
The Most Important Feature of Corrugated Cardboard
The key advantage of corrugated cardboard is its high strength compared to its low weight. In other words, it is a lightweight yet durable material that can absorb impacts and resist deformation. Because of this, it is widely used for packaging household appliances, audio equipment, TVs, and other large products.
Structure of Corrugated Cardboard
Corrugated cardboard can come in many variants. The simplest is the two-layer version, while the most complex can have up to seven layers. Two-layer micro-flute consists of an outer smooth layer, often called the liner, and an inner fluted layer that gives the material its cushioning properties.
Outer liners: These are two sheets surrounding the fluted layer. They ensure durability, rigidity, and excellent printability for offset printing.
Flute: Located between the liners, it gives the material its characteristic wave shape and, more importantly, provides cushioning properties.
Two-Layer Corrugated Cardboard
As the name suggests, this type consists of one flat and one fluted liner. It is available in gray or white versions and has a grammage of 240 g. We use it for large production runs, where both quality and price are essential. The cardboard is laminated with prints on mmliner, kraftliner, or GD2 board. You will often find products packed in such boxes on store shelves.
- F Flute — height: approx. 0.9–1.2 mm
- E Flute (microflute) — height: approx. 1.2–2 mm
- B Flute — height: approx. 2.4–3 mm
- C Flute — height: approx. 3.5–4 mm
- Color variants: gray–gray, white–white, white–gray
Three-Layer Corrugated Cardboard
Three-layer corrugated cardboard is the material we use most frequently for laminated packaging with offset printing, flexographic printing, or transport boxes. It can be covered with printed sheets of almost any paper or board and finished with film, UV varnish, embossing, or hot stamping. This allows us to create both elegant gift packaging and durable shipping boxes.
- F Flute — height: approx. 0.9–1.2 mm, grammage 240–300 g/m²
- E Flute — height: approx. 1.2–2 mm, grammage 346–490 g/m²
- B Flute — height: approx. 2.4–3 mm, grammage 277–580 g/m²
- C Flute — height: approx. 3.5–4 mm, grammage 400–590 g/m²
- Color variants: gray–gray, white–white, white–gray
Five-Layer Corrugated Cardboard
Modern industry also requires stronger and more demanding bookbinding materials, such as five-layer corrugated cardboard. There are two main types used most commonly:
- EB Flute — height: approx. 5 mm, grammage 650–850 g/m²
- BC Flute — height: approx. 6–7 mm, grammage 690–1500 g/m²
Strength Tests and Measurements
To ensure consistent quality, corrugated cardboard and packaging are tested using standardized strength measurements:
- FCT (Flat Crush Test): Measures the force required to crush the flutes while the sheet is laid flat. This indicates resistance to impact or puncture.
- ECT (Edge Crush Test): Measures the force required to break the sheet when placed vertically. This shows how well the packaging withstands stacking.
- BCT (Box Compression Test): Measures the force required to crush a box between two plates. This determines box strength under pressure.
Corrugated cardboard is a key raw material in modern packaging production. Because it combines strength, lightness, and cost efficiency, it remains one of the most popular choices in the packaging industry.
Looking for Durable Packaging Solutions?
If you are searching for high-quality packaging made from durable and lightweight materials, we are ready to help. We offer custom solutions using corrugated cardboard that perfectly combine strength and elegant design. Contact us today to discuss your packaging needs!