Corrugated Packaging Manufacturing
Teal Packaging produces corrugated packaging for businesses requiring durable, cost-effective shipping containers.
Our corrugated boxes combine strength, cushioning, and customization to protect products during warehouse storage, transportation, and final delivery. We make single-wall, double-wall, and triple-wall corrugated in all standard flute profiles.
Corrugated Construction Basics
Corrugated board consists of multiple layers:
- Linerboard: flat paper sheets forming exterior and interior surfaces
- Fluting (medium): wavy paper layer providing cushioning and strength
- Single-wall: two linerboards with one flute layer between (most common)
- Double-wall: three linerboards with two flute layers (heavy-duty applications)
- Triple-wall: four linerboards with three flute layers (industrial/export shipping)
Flute Profiles
Flute size affects cushioning, stacking strength, and printability:
- A-flute (5mm): excellent cushioning, fragile products, limited stacking
- B-flute (3mm): good compression strength, smooth print surface, die-cutting friendly
- C-flute (4mm): industry standard, balanced strength and cushioning
- E-flute (1.5mm): retail-quality printing, folding carton alternative
- F-flute (0.8mm): thinnest profile, mailer boxes, minimal bulk
- BC-flute (double-wall): heavy products, tall stacks, long-distance shipping
Board Grade and Strength
Edge Crush Test (ECT) rating measures stacking strength:
- 23 ECT: light products up to 20 lbs, low stacking
- 26 ECT: replaces 125 lb burst test, 30 lbs per square inch
- 32 ECT: most common grade, 40 lbs PSI, general shipping
- 44 ECT: heavy products, 60 lbs PSI, high stacking requirements
- 48 ECT: replaces 200 lb burst test, demanding applications
- 51 ECT: double-wall standard, 80 lbs PSI
- 61 ECT: industrial applications, 90 lbs PSI
- 71 ECT: triple-wall, export containers, 100 lbs PSI
Box Styles and Configurations
Corrugated boxes are manufactured in multiple structural styles:
- RSC (Regular Slotted Container): most economical, outer flaps meet at center
- FOL (Full Overlap): flaps overlap completely, added strength for heavy products
- HSC (Half-Slotted Container): open top, high-speed automated filling
- Self-locking: die-cut tabs eliminate tape requirement
- Telescope (two-piece): separate lid and base, reusable shipping
- Die-cut custom: tailored to exact product dimensions
Printing Options
Corrugated packaging accepts multiple printing processes:
- Flexographic printing: 1-4 spot colors, cost-effective, fast turnaround
- Litho-lamination: full-color CMYK printed sheet laminated to corrugated
- Digital printing: full-color for short runs, no plate costs
- Pre-print: high-volume runs with graphics printed before box manufacturing
Finishing and Features
Corrugated boxes can include specialized features:
- Die-cut windows with clear film for product visibility
- Handles (hand holes or rope handles)
- Perforated tear strips for easy opening
- Interior dividers for multi-product shipping
- Wax or poly coating for moisture resistance (reduces recyclability)
- Custom die-cut shapes matching product contours
Pricing Structure
Corrugated box pricing depends on dimensions, board grade, printing. And quantity. Standard RSC boxes (C-flute, 32 ECT) start at $0.70 per unit for 500 pieces (12" x 10" x 8"). Double-wall boxes start at $1.15 per unit. Adding flexographic printing (two colors) adds $0.18-$0.25 per unit. Die-cut custom shapes add $0.30-$0.50 per unit. Volume discounts: 1,000 pieces reduces cost by 17%, 2,500 by 25%, 5,000 by 33%, 10,000 by 42%.
Production Requirements
Minimum order quantity: 100 units. Standard production turnaround: 15-20 business days after artwork approval. Rush production available (8-10 days) for 30% premium. We require interior dimensions (length x width x depth), product weight, stacking height requirements. And printing specifications. For custom die-cut boxes, provide product samples or detailed dimensional drawings.
Applications by Industry
Corrugated packaging serves diverse shipping needs:
- Ecommerce fulfillment: product shipping boxes for online retailers
- Food distribution: dry goods, produce, frozen food (wax-coated)
- Electronics: custom foam inserts for fragile components
- Automotive: parts distribution, aftermarket accessories
- Industrial: machinery components, tools, hardware
- Pharmaceuticals: secondary packaging for temperature-controlled shipments
- Retail: shelf-ready displays with perforated sections
- Agriculture: produce boxes with ventilation holes
Sizing Optimization
Proper box dimensions reduce costs and improve protection:
- Tight fit: product plus 0.5-1" clearance minimizes material waste
- Dimensional weight: oversized boxes incur shipping surcharges
- Pallet optimization: dimensions that stack efficiently on 48" x 40" pallets
- Cube use: maximize trailer and container space
- Standard vs. custom: stock sizes often more economical for small quantities
Testing and Quality Control
Corrugated packaging undergoes rigorous performance testing:
- Edge crush test (ECT): verifies board grade meets specifications
- Compression test: measures stacking strength under load
- Drop test: simulates handling damage during shipping
- Bursting strength: resistance to internal pressure
- Moisture resistance: humidity exposure to verify integrity
- Print quality: color accuracy and registration verification
Environmental Considerations
Corrugated packaging is inherently sustainable:
- 89% recycling rate (highest of any packaging material)
- Biodegradable in landfill environments
- FSC-certified options from responsibly managed forests
- Recycled content available (30% to 100% post-consumer fiber)
- Renewable resource (trees regrow, unlike petroleum-based plastics)
- Low carbon footprint vs. alternative materials
Design and Engineering Services
Our packaging engineers optimize corrugated box designs:
- Load testing: calculate appropriate ECT rating for product weight and stacking
- Dimension optimization: minimize material while ensuring protection
- Compression analysis: predict box performance under warehouse conditions
- Cushioning design: recommend void fill or inserts for fragile products
- Cost modeling: compare material grades and styles for budget efficiency
Engineering consultations are complimentary with quote requests. Full structural design services (custom die-cutting, prototypes) range from $200-$600.
Prototyping and Sampling
Physical samples ensure proper fit and function:
- White samples: unprinted boxes for fit testing ($30-$50 per sample)
- Printed samples: full graphics for presentation ($70-$110 per sample)
- Pre-production samples: first units from production run (complimentary)
- Load testing: compression and drop testing with actual products ($150-$300)
Inventory Management
Corrugated boxes ship flat (knocked down) for space-efficient storage:
- Warehouse footprint: 50 flat boxes occupy space of 3-5 assembled boxes
- Assembly time: RSC boxes assemble in 6-10 seconds per unit
- Bundling: boxes packaged in sets of 25-50 for handling convenience
- Pallet stacking: standard pallets hold 500-2,000 flat boxes depending on size
- Shelf life: corrugated boxes have indefinite shelf life in dry storage
Ordering Process
Submit corrugated packaging specifications through our quote request form. Include product dimensions and weight, annual volume estimate, stacking requirements, and printing needs.
Our team responds within 4 business hours with board grade recommendations, pricing for multiple quantities, and production timeline. Browse our product catalog for corrugated box styles.
Shipping and Logistics
Corrugated boxes ship via freight carrier on pallets. Standard shipments include protective wrapping, corner boards. And strapping. Typical freight costs for 1,000 RSC boxes (12x10x8) to East Coast destinations: $150-$200. West Coast: $230-$290. Midwest: $120-$170. Samples ship via UPS Ground within 2 business days.
Ready to source corrugated packaging that protects products and controls costs? Request a quote and receive detailed specifications within 4 hours.
