Corrugated and Shipping Boxes Made for the Road

What are corrugated shipping boxes?

Corrugated board is a sandwich. Two flat paper liners hold a rippled layer called the flute. That ripple gives the board spring, so it takes a knock and bounces back.

This range covers sixteen boxes that travel: warehouse cartons, heavy double wall cases, and boxes shaped for books, mugs, prints and records. Every one is made to the inside size you give us.

Board, flute and style are picked for each job. Two boxes with the same footprint can behave very differently on a truck, so we ask what goes inside before we quote.

Not sure where to begin? Most buyers start with made-to-size corrugated cartons, the general-purpose box that the other styles build on.

Which shipping box fits which job?

Read across a row to match your product to a style. The last column shows what makes each box different from the rest.

Slotted, overlap or folding: which style do I need?

The slotted carton is the workhorse. Four flaps fold down, and the two long ones meet in the center. It uses little board, so the cost per box stays low.

Cut the top flaps off and you get a half slotted container. It stays open for picking or pairs with a separate lid. On a full overlap container, the long flaps cover the whole top, which doubles the board for heavy loads.

Folding styles such as the tuck front need no tape and open like a gift. For bulk stock, a regular slotted container cut to size is usually the lowest cost per cubic foot.

When should I choose double wall board?

Single wall handles most packages. Step up to BC double wall, about 1/4 in (7 mm) thick, in three cases. The box is heavy, it sits at the bottom of a stack, or the contents can break.

Double wall also suits long trips with many handoffs. Each transfer is another chance for a corner to give way. Our double wall boxes for heavy loads page shows common sizes.

Double wall adds thickness and outside size. Check that the larger carton does not push your packages into a higher shipping rate tier.

What inside size should a shipping box be?

Measure the product at its widest points, including any wrap or tissue. Write the size as inside length, width and height in inches.

For fragile goods, leave 1 1/4 to 2 in on every side for cushioning. For books, apparel and other sturdy items, 1/4 to 3/8 in is usually enough.

Height runs from the opening down to the base. A box that opens on the long side has a different height than one that opens on the end. A 12 × 9 × 4 in box suits a folded sweater.

Our guide on measuring the inside of a box explains which side counts as length.

Can corrugated shipping boxes be printed?

Yes. Corrugated takes print well. Many boxes ship with a one color logo on brown kraft. It is quick to set up and reads clearly on a porch.

For more color, choose two color or full color CMYK on white or kraft board. Inside print adds a thank-you note without changing the plain look outside. Examples appear on our flat art mailing boxes with print.

Our designers lay out the artwork for free. You see a design proof before anything is printed.

What mistakes damage boxes in transit?

Most damage comes from three things: a box that is too big, board that is too thin, and goods that shift. Fix those and breakage drops.

Oversized boxes are the hidden cost. Empty space needs filler, and a big box can cave in under a heavy neighbor. For valuable goods, a retention box that holds the product suspends it away from all six walls.

Weak taping is the other usual fault. Run tape down the center seam and over both edges, not a single strip.

Test before a busy season. Pack one box with real goods and drop it onto a corner from waist height. Open it. A shifted or cracked item means the fit or the board needs to change.

How should I store and pack flat cartons?

Boxes arrive flat to save space. Keep them dry and off a cold concrete floor, since damp board loses stiffness fast.

Fold along the creases, not across them. Square the box before taping, because a skewed carton stacks badly and is weaker at the corners.

Shops that ship media should keep book shipping boxes in common sizes beside the packing table.

Stand flat bundles on their edges instead of face down under weight. A heavy load can crush the flutes before you ever fold the box.