HOW TO MEASURE A BOX
The size of a corrugated box is always in the sequence… Length x Width x Depth (Height). These are the inside dimensions are are used in determining the proper size of box to ensure a good fit for the product.
With the box open:
- The LENGTH is the measurement of the longest side of the rectangle
- The WIDTH is the measurement of the shorter side of the rectangle
- The DEPTH or HEIGHT is the measurement of the side perpendicular to the ground and/or opening.
BOX STYLES
When it comes to corrugated boxes, there are a lot of different options to choose from. It can often be overwhelming to dig through the choices for the optimal solution. That’s why we’ve put together this complete guide to the different types of corrugated boxes. Below, you’ll learn about the styles of boxes, as well as what flute type would best suit your needs. Whether you’re in e-commerce, manufacturing, or retail, understanding these box types is essential for optimizing your packaging strategy.
Corrugated boxes come in various types tailored to specific needs. Among the most common types are the regular slotted container, half-slotted container, full overlap slotted container, die-cut boxes, and telescoping boxes.
RSC – Regular Slotted Container
RSCs are the most common box style due to their highly efficient design. You will find four flaps on both ends of the structure, each measuring half the width of the box. The outer flaps (typically the lengthwise ones) meet in the center when folded, creating a sturdy and balanced carton. RSCs provide protection as the contents within are completely enclosed. You’ll commonly see RSCs used as shipping boxes because of their streamlined nature.
Half-Slotted Container (HSC)
An HSC is similar to an RSC, however it only features flaps on one end of the structure while the other end remains open. Its flaps, each half the size of the box width, join in the middle when folded and are typically secured with tape or staples. With only one set of flaps, HSCs enable quick access to the contents within the carton.
Full Overlap Slotted Container (FOL)
Unlike RSCs and HSCs where the flaps meet in the middle, FOLs have extended flaps allowing them to completely overlap each other when folded. This overlapping design provides an additional layer of protection on both the top and bottom of the box. Because of their durability, these boxes are commonly used for industrial equipment, machinery, automotive parts, and other heavy-duty applications.
Die-Cut Boxes
Die-cut boxes are a great choice for applications that require more customization. An engineer will design a carton specific to your needs and then a custom cutting die will be used to produce the final box. This process allows for intricate designs and a secure fit for your product, providing a truly tailored packaging solution. Die-cut boxes are perfect for a wide range of products, and are most commonly used for e-commerce and retail packaging.
Telescoping Boxes
A telescoping box consists of two parts: an outer structure that slides over an inner structure, creating a telescoping effect. As these boxes can expand up to three times their size, they’re ideal for large, long, or oddly shaped objects. Some examples include pipes, machinery, and appliances.
Partitions
Partitions are great for keeping product separated.
Pads / Scored Sheets
Flutes
Flutes are the waves that define corrugated paper/cardboard. The most common Flute sizes are, A, B, C, E and F or Micro-flute. The letter designation does not relate to the size of the flute but to the order in which they were invented. Flute size or height refers to the number of flutes (waves) per lineal foot with C & B being most common.
B flute
- offers excellent crush resistance
- allows for high print quality
- has a lower wave height and more flutes per foot, creating a rigid surface with more points of support
- reduces storage space
C flute
- is the most popular flute size
- is thicker than the B flute
- provides excellent stacking and cushioning features
E flute
- offers the largest number of flutes per foot
- is very thin
- allows for high-quality printing
- resists crushing and other damage
Single-wall Construction
A single wall consists of a corrugated sheet between two flat sheets known as linerboards. This durable and widely used construction is also known as a doable face sheet and comes in a number of strengths (see Tests).
Double-wall Construction
A double wall consists of two corrugated sheets and three linerboards. The corrugated sheets are usually laminated and interleaved with the linerboard. This provides extra protection and rigidity, ideal for packaging and stacking heavy items.
TESTS & STRENGTHS
Two tests measure the strength of a corrugated board: the bursting test and the edge-crush test. The bursting test evaluates the bursting strength of a board. Bursting strength is the force required to break through the board and indicates the box’s ability to withstand both internal and external pressure. Similarly, the edge-crush test evaluates the edge-crush strength of the board. Edge-crush strength is the amount of force required to crush the board’s edge and predicts the overall compression strength of the finished box.
Start with the weight of your contents to determine the strength of corrugated material you require, as indicated in the chart below:
Single Wall Corrugated Boxes:
| Maximum weight of box and contents (lbs.) | Minimum bursting test Single Wall, Double Wall | Minimum edge crush |
|---|---|---|
| 20 | 125 | 23 |
| 35 | 150 | 26 |
| 50 | 175 | 29 |
| 65 | 200 | 32 |
| 80 | 250 | 40 |
| 95 | 275 | 44 |
| 120 | 350 | 55 |
Double Wall Corrugated Boxes:
| Maximum weight of box and contents (lbs.) | Minimum bursting test Single Wall, Double Wall | Minimum edge crush |
|---|---|---|
| 80 | 200 | 42 |
| 100 | 275 | 48 |
| 120 | 350 | 51 |
| 140 | 400 | 61 |
| 160 | 500 | 71 |
| 180 | 600 | 82 |
