Corrugated Cardboard Material Guide By Buy Packaging Boxes

Author | Date: 11/5/2025

Corrugated Cardboard: The Unsung Hero of Packaging

Whether it’s a pizza box, a candle mailer, or a subscription kit, chances are it’s made from corrugated cardboard. It’s durable, printable, cost-effective, and easy to recycle. The trick is choosing the right grade and flute for your product, so you get enough protection without overspending on material or shipping. A lightweight candle sleeve doesn’t need the same strength as a box for small electronics — and that’s exactly what this guide helps you decide.

What Is Corrugated Cardboard? (Definition & Structure)

Corrugated cardboard is a sandwich: a fluted medium in the middle, bonded to flat linerboards on one or both sides.

Linerboard: the smooth outer/inner faces that carry print.
Fluting: the wavy middle layer that creates cushioning, crush resistance, and stacking strength.

Common flute profiles:

A (thick, cushioned), B (crush-resistant), C (balanced all-rounder), E (thin, great print), F (ultra-thin, premium print).

Why it works: high strength-to-weight ratio, shock absorption, recyclability, and excellent print surfaces (kraft or white).

Understanding sizes helps strength too. See Box Sizes & Dimensions Guide.

Types of Corrugated Cardboard (By Wall Construction)

Single Wall (Most common)

Build: 1 fluted medium + 2 liners
Pros: light, economical, highly printable
Best for: cosmetics, candles, FMCG, subscription mailers

Double Wall (Heavier duty)

Build: 2 fluted mediums + 3 liners
Pros: higher crush/stack strength, better puncture resistance
Best for: electronics, food hampers, multi-item kits, longer transit routes

Triple Wall (Industrial)

Build: 3 fluted mediums + 4 liners
Pros: pallet-grade strength, export packaging, near wood-crate performance

Best for: machinery, heavy components, stacked pallets

💡 Pro Tip

Shipping internationally or stacking high? Step up to double or triple wall to prevent panel bulge and collapse.

Corrugated Flute Types and Their Uses

Flute	Approx. Thickness	Characteristics	Best For
A	~4.8 mm	Maximum cushioning	Fragile items, void-sensitive goods
B	~3.2 mm	High crush resistance, tighter flutes	Retail cartons, die-cuts
C	~4.0 mm	Balanced: cushion + compression	General shipping boxes
E	~1.6 mm	Thin, smooth, great for print	Cosmetic/retail, mailers
F	~0.8 mm	Ultra-thin, premium surfaces	Luxury sleeves, small cartons

💡 Design Note

A popular combo is EB (E + B) — E on the print side for a smooth finish, B behind it for strength.

Corrugated Cardboard Grades — What They Mean

Grades indicate strength and performance, usually via two tests:

ECT (Edge Crush Test): stacking/column strength (e.g., 32 ECT, 44 ECT, 48 ECT, 61 ECT).
Burst (Mullen) Test: puncture/rupture resistance under pressure (e.g., 200#, 275#, 350#).

Typical mappings & use cases:

Single Wall 32 ECT / 200# burst: light retail/eCommerce, up to ~10–15 kg depending on pack design.
Double Wall 44–48 ECT / 275# burst: medium-duty shipping, heavier SKUs, wider distribution.
Triple Wall 61 ECT+ / 350# burst: industrial loads, export, tall stacks.

Rule of thumb: a 32 ECT shipper can support roughly ~65 lb (~29 kg) of stacked weight in ideal conditions, but actual performance depends on box size, flute, humidity, and stacking time. Always validate with your supplier.

Characteristics of Corrugated Cardboard

Durable & shock-absorbing: protects against drops and racking.
Lightweight: reduces freight and handling costs.
Highly printable: kraft (natural) or white (bright print), accepts laminations and coatings.
Eco-friendly: recycled content, recyclable, biodegradable, FSC® options.
Customisable: flute, wall, board grade, coatings, and inserts tailored to product.

Finishing matters. See Packaging Laminations: Matte, Gloss, Soft-Touch.

Corrugated Cardboard Rolls and Sheets — When to Use Them

Sheets: convert into custom die-cuts or non-standard sizes quickly; ideal for short-run or bespoke trays.
Rolls: flexible single-face corrugated for wrapping bottles, ceramics, or irregular objects; great as eco void fill.

Applications and Uses

Shipping cartons & eCommerce mailers
Retail-ready packaging & display sleeves
POP displays and dump bins
Food delivery/pizza boxes
Gift sets and custom printed boxes
Protective inserts: dividers, nests, pulp alternatives

💡 Pro Tip

Corrugated can replace plastic foams using die-cut inserts or honeycomb boards for a fully paper-based pack.

Choosing the Right Corrugated Material for Your Packaging

Consider these four:

Product weight & fragility: heavier/fragile needs higher ECT, double or triple wall, or stronger flute.
Journey & stacking: long routes, humidity, and pallet stacking increase strength requirements.
Branding & print: choose white-lined E/E-flute for premium print, or kraft for eco aesthetics.
Budget & sustainability: right-sizing and correct grade cut costs and carbon.

Explore Custom Cardboard Boxes built to your exact dimensions.

Sustainability of Corrugated Cardboard

Corrugated is made from recycled fibres and renewable pulp, is 100% recyclable, and widely accepted in kerbside collections. Ask for FSC®-certified liners, water-based inks, and right-size geometry to lower total material and emissions.

Want a greener spec? Ask about FSC® liners, high-recycled content, and plastic-free protection options.

Final Thoughts — Know Your Material, Protect Your Product

Pick flute + wall + grade to match the job: that’s the formula for fewer damages, lower shipping costs, and a better unboxing. If in doubt, prototype and test.

Need a recommendation? The team at Buy Packaging Boxes will spec the right corrugated grade, provide samples, and print to your brand standards.

👉 Get a tailored quote or Browse Custom Corrugated Boxes.

No More Confusion: Understanding Corrugated Cardboard

What is corrugated cardboard made of?

Two or more linerboards bonded to a fluted paper medium — the fluting adds strength and cushioning.

What’s the difference between cardboard and corrugated cardboard?

“Cardboard” is a loose term for thick paperboard; corrugated includes a fluted core between liners for much higher strength.

What are the main types of corrugated?

Single wall, double wall, and triple wall — each adds another fluted layer and liner for more strength.

Which flute type is strongest?

For cushioning, A-flute is thickest; for crush resistance, B-flute is great; C-flute balances both; E/F-flute excel at print and compact packs.

Is corrugated cardboard eco-friendly?

Yes. It typically contains recycled fibre, is fully recyclable, and can be sourced as FSC®-certified.